Safety and security in transformation

Recent reports paint a stark picture. Manufacturing is consistently ranked among the sectors targeted the most globally by cyber criminals. Attack vectors are multiplying, moving beyond traditional IT systems to directly target operational technology (OT), the systems that control physical processes and machinery. Analysis shows a significant surge in attacks specifically aimed at disrupting industrial control systems (ICS).

The consequences are far more severe than data theft. A successful cyber intrusion can lead to physical damage to equipment, environmental incidents, prolonged and costly production downtime (often measured in days or even weeks for complex manufacturing setups), significant financial losses, and severe reputational damage. Crucially, by manipulating control systems that govern machine movements, safety interlocks, and emergency stops, these attacks can directly compromise safety functions and safeguards, turning traditional machinery safety risks into realised catastrophic events that endanger your most valuable asset: your people.

This interconnectedness means that the security of your digital infrastructure is no longer separate from the physical safety of your plant and personnel. True machinery safety in the modern age requires robust industrial security. The principle is undeniable: there is no safety without security. Regulators globally are recognising this, with new requirements explicitly linking security to safety compliance, signalling a direction Australian manufacturers must also urgently address.

The growing regulatory imperative — with safety as the driver

While Australia has its own robust safety frameworks, the global regulatory environment is increasingly reflecting this integrated view, often driven by the recognition of cyber risks to safety. Developments overseas, such as the updated EU Machinery Regulation (becoming mandatory in early 2027), explicitly incorporate security requirements as an essential part of machinery design and operation, specifically citing the potential for malicious attacks to compromise safety. Other international specifications like the IEC 62443 series for Industrial Security, ISO/IEC TS 63074, and the broader principles of ISO 27001, alongside directives like NIS-2 and the upcoming Cyber Resilience Act (CRA) in Europe, signal a clear global trend towards mandatory security as a prerequisite for safety.

This trend isn’t just about navigating international trade; it highlights a fundamental shift in best practice and risk management that manufacturers must embrace proactively. Staying ahead of this curve isn’t merely about potential future compliance; it’s about fortifying your operations now against present and future threats to ensure the continued safety of your workforce.

Adopting a holistic approach for comprehensive protection

Given the complexity and the high stakes — including personnel safety — where do decision-makers begin? The key is to view safety and security holistically and address them early in the lifecycle of machinery and plant design, implementation, and operation. Treating them separately leads to gaps, inefficiencies, and increased risk that could compromise both operational integrity and worker safety.

This is where partnering with an expert like Pilz becomes invaluable. With deep roots in machinery safety, Pilz has evolved to understand and address the converged requirements of safety and security in the industrial space. It offers a comprehensive suite of support measures designed specifically for decision-makers navigating this complex landscape, always with the protection of personnel as a paramount concern.

Pilz: your partner for integrated safety and security — protecting people and plant

Pilz understands that ensuring safe, compliant, and secure machinery requires a multi-faceted approach that prioritises personnel protection. Pilz provides a one-stop solution encompassing:

1. Knowledge of the standards — The Pilz expertise

The foundation of compliance and safety is understanding the requirements. Pilz offers extensive expertise in interpreting complex national and international standards and regulations, including the evolving security standards and their impact on safety.

• Information on the Machinery Regulation
• Information on the series of Security Standards IEC 62443

2. Training courses from beginner to expert level

Through training on machinery safety and industrial security, your team learns how cyber risks can directly impact physical safety and how to mitigate those dangers. Knowledge truly is your first line of defence for both the system and the people operating it.

• Fundamentals of Machinery Safety
• Introduction to Machinery Regulation
• Fundamentals of Industrial Security
• CESA – Certified Expert in Security for Automation

3. Integrated consulting and engineering services

Addressing safety and security requires a structured, methodical approach that considers the safety of personnel at every step. Pilz offers consulting and engineering services that seamlessly integrate the process steps for both disciplines. From joint risk and threat assessments (evaluating how cyber threats could lead to unsafe conditions), defining requirements, designing protective measures, to implementation and validation — a proven methodology covers both perspectives with efficiency and thoroughness. Available services are:

• Machine Safety Evaluation
• Conformity Assessment of Machinery
• ISCS – Industrial Security Consulting Service

4. Product solutions for safety and security

Pilz offers innovative product solutions that bridge the gap between traditional safety components and modern security requirements. The Identification and Access Management (IAM) portfolio, for example, provides robust solutions that control who can access and operate machinery functions. This directly enhances personnel safety by ensuring only authorised, trained personnel can access and operate specific machinery functions, preventing unintended, incorrect, or malicious actions that could bypass safeguards and lead to accidents. These solutions help protect employees, prevent liability issues, maximise productivity by controlling access effectively, and safeguard critical data and intellectual property, all while reinforcing the safety barrier.

The result: safe, compliant, resilient operations

The integration of industrial security into machinery safety is not a distant concept; it is a present necessity for any Australian manufacturing business looking to thrive safely in the connected world. By embracing this reality and partnering with a provider offering expertise, integrated services, and suitable technologies, decision-makers can confidently navigate the route to safe, compliant, and resilient operations, ensuring their people are protected above all else.

Pilz stands ready to be your partner on this crucial journey, offering competent, comprehensive support from initial assessment and training through to integrated system implementation, always with personnel safety at the forefront.