Robotic Cell Safety & Commissioning Checklist

{ "Title": "Robotic Cell Safety & Commissioning Checklist", "IntroductionHtml": "

Purpose

Use this checklist to record a baseline safety commissioning for a robotic cell. It is intended to document physical safeguards, control logic verification, training, maintenance access, and required documentation so teams have an auditable commissioning record. This checklist is a practical aid — it does not replace formal risk assessment, certified safety reviews, or regulatory compliance activities.

How to use

Answer each item, add observations for any non-conformance, assign corrective actions when needed, and attach supporting documentation to the equipment history after saving. Use ISO/ANSI/OSHA standards and your organization’s risk assessment as the authoritative references.

", "SubmitLabel": "Save commissioning record", "SuccessMessage": "Commissioning record saved. Review and attach supporting documents to the equipment history. Assigned corrective actions will appear in the team action list.", "DataType": "RoboticCellCommissioningChecklist", "SchemaVersion": 1, "Fields": [ { "Key": "commissioning_date", "Type": "text", "Label": "Commissioning date", "Required": true, "HelpText": "Enter date as YYYY-MM-DD" }, { "Key": "equipment_id", "Type": "text", "Label": "Equipment / cell identifier", "Required": true, "HelpText": "Asset tag, line number, or unique equipment ID" }, { "Key": "location", "Type": "text", "Label": "Location", "HelpText": "Plant / cell / bay" }, { "Key": "responsible_engineer", "Type": "text", "Label": "Responsible commissioning engineer / lead", "Required": true }, { "Key": "reviewer", "Type": "text", "Label": "Independent reviewer (safety/QA)", "HelpText": "Name of person who independently reviewed the checks" }, { "Key": "safety_area_clear", "Type": "select", "Label": "Safety area clear of nonessential personnel", "Required": true, "Options": [ {"Value": "pass", "Label": "Pass"}, {"Value": "fail", "Label": "Fail"}, {"Value": "na", "Label": "N/A"} ] }, { "Key": "guarding_installed", "Type": "select", "Label": "Physical guarding installed and secure (fixed guards, fences)", "Options": [ {"Value": "pass", "Label": "Pass"}, {"Value": "fail", "Label": "Fail"}, {"Value": "na", "Label": "N/A"} ] }, { "Key": "guarding_interlocks", "Type": "select", "Label": "Access doors / gates have functional interlocks", "Options": [ {"Value": "pass", "Label": "Pass"}, {"Value": "fail", "Label": "Fail"}, {"Value": "na", "Label": "N/A"} ], "HelpText": "Where doors exist, confirm interlocks stop hazardous motion and prevent restart until safe" }, { "Key": "estop_functional", "Type": "select", "Label": "Emergency stop(s) functional and accessible", "Options": [ {"Value": "pass", "Label": "Pass"}, {"Value": "fail", "Label": "Fail"} ], "Required": true }, { "Key": "interlocks_by_design", "Type": "select", "Label": "Interlock logic aligns with documented safety design", "Options": [ {"Value": "yes", "Label": "Yes"}, {"Value": "no", "Label": "No"}, {"Value": "partial", "Label": "Partial / Conditional"} ] }, { "Key": "electrical_termination", "Type": "select", "Label": "Electrical terminations and guarding checked (no exposed conductors)", "Options": [ {"Value": "pass", "Label": "Pass"}, {"Value": "fail", "Label": "Fail"} ] }, { "Key": "safety_control_logic_verified", "Type": "select", "Label": "Safety control logic (SIL/PL where applicable) functionally verified", "Options": [ {"Value": "pass", "Label": "Pass"}, {"Value": "fail", "Label": "Fail"}, {"Value": "na", "Label": "N/A"} ], "HelpText": "Includes verified behavior on faults, e-stop, and safety zone entry" }, { "Key": "safety_controller_program_reviewed", "Type": "yesno", "Label": "Safety controller program / safety-rated PLC reviewed by qualified person", "HelpText": "Yes = reviewed; No = requires review" }, { "Key": "presence_sensing_devices", "Type": "select", "Label": "Presence sensing devices (light curtains, mats, scanners) correctly installed and tested", "Options": [ {"Value": "pass", "Label": "Pass"}, {"Value": "fail", "Label": "Fail"}, {"Value": "na", "Label": "N/A"} ] }, { "Key": "cobot_force_limits", "Type": "select", "Label": "For collaborative robots: force/torque limits and speed monitoring verified", "Options": [ {"Value": "verified", "Label": "Verified"}, {"Value": "not_verified", "Label": "Not verified"}, {"Value": "na", "Label": "N/A"} ] }, { "Key": "loto_procedure_defined", "Type": "yesno", "Label": "Lockout/Tagout (LOTO) procedure defined for maintenance", "HelpText": "Yes if LOTO steps are documented and accessible" }, { "Key": "maintenance_access", "Type": "select", "Label": "Maintenance access (panels, clearances) meets requirements", "Options": [ {"Value": "adequate", "Label": "Adequate"}, {"Value": "restricted", "Label": "Restricted / needs change"}, {"Value": "blocked", "Label": "Blocked / unsafe"} ] }, { "Key": "operator_training", "Type": "yesno", "Label": "Operator training completed on safe operation and emergency procedures", "HelpText": "Yes = training completed and recorded" }, { "Key": "spare_parts_documented", "Type": "yesno", "Label": "Critical spare parts and consumables documented", "HelpText": "Helps reduce downtime" }, { "Key": "documentation_attached", "Type": "yesno", "Label": "Required documentation attached (schematics, wiring, safety assessment, manuals)", "HelpText": "Attach files to equipment history after saving" }, { "Key": "risk_assessment_on_file", "Type": "yesno", "Label": "Risk assessment / ISO 12100 / other hazard analysis on file", "HelpText": "Yes if formal assessment exists" }, { "Key": "non_conformances", "Type": "textarea", "Label": "Non-conformances or observations", "HelpText": "For each non-conformance, describe the issue, location, and immediate risk" }, { "Key": "corrective_action_owner", "Type": "text", "Label": "Corrective action owner", "HelpText": "Person responsible for resolving non-conformance" }, { "Key": "corrective_action_due", "Type": "text", "Label": "Corrective action due date", "HelpText": "Enter date as YYYY-MM-DD" }, { "Key": "attachments_instructions", "Type": "textarea", "Label": "Attachments and evidence", "HelpText": "List file names to attach to equipment history (risk assessment, test logs, screenshots, photos, training records)" }, { "Key": "final_approval", "Type": "select", "Label": "Final commissioning decision", "Options": [ {"Value": "approved", "Label": "Approve: Ready for production"}, {"Value": "conditional", "Label": "Conditional: Hold until actions completed"}, {"Value": "rejected", "Label": "Reject: Not safe for operation"} ], "Required": true }, { "Key": "approver_name", "Type": "text", "Label": "Approver name & role", "Required": true }, { "Key": "approver_signature", "Type": "text", "Label": "Approver signature (typed name)", "HelpText": "Typed name serves as an auditable approval record" }, { "Key": "overall_readiness", "Type": "scale", "Label": "Overall readiness (1 = Not ready, 5 = Fully ready)", "HelpText": "Use to quickly rate the cell readiness", "Required": false, "ScaleMin": 1, "ScaleMax": 5 }, { "Key": "notes", "Type": "textarea", "Label": "Additional notes / recommendations", "HelpText": "Any other observations useful for operations, safety, or maintenance" } ] }