Robotic Cell Safety & Layout Checklist

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

This interactive checklist helps teams validate robotic cell layout, safeguards, controls, sensing, access, training, and daily inspection tasks before commissioning and during routine operation. It is a practical aid — not a substitute for a formal risk assessment, certified safety review, or regulatory compliance. Use it to capture findings, corrective actions, responsible owners, and sign-offs.

", "SubmitLabel": "Save Checklist", "SuccessMessage": "Checklist saved. Use this record for commissioning evidence and follow-up actions.", "DataType": "RoboticCellSafetyChecklist", "SchemaVersion": "1.0", "Fields": [ { "Key": "site_location", "FieldType": "text", "Label": "Site / Plant / Cell", "HelpText": "Identify the plant, line, or cell location (e.g., Plant A – Line 3 – Cell 2).", "Required": true }, { "Key": "inspector_name", "FieldType": "text", "Label": "Inspected by (name)", "HelpText": "Person completing the checklist.", "Required": true }, { "Key": "inspection_date", "FieldType": "text", "Label": "Date", "HelpText": "YYYY-MM-DD", "Required": true }, { "Key": "layout_validation", "FieldType": "yesno", "Label": "Layout validated for safe human access and maintenance", "HelpText": "Verify clear maintenance access, unblocked egress, and no pinch/entrapment pathways.", "Required": true }, { "Key": "layout_notes", "FieldType": "textarea", "Label": "Layout notes / issues", "HelpText": "Describe obstructions, clearance shortfalls, or proposed changes." }, { "Key": "reach_and_singulation", "FieldType": "yesno", "Label": "Reach / singulation hazards considered", "HelpText": "Have reach zones and singulation (situations where a person might be within a robot's work envelope) been identified and mitigated?", "Required": true }, { "Key": "reach_notes", "FieldType": "textarea", "Label": "Reach/singulation mitigation notes", "HelpText": "Describe barriers, procedures, or sensors used to prevent human entry during motion." }, { "Key": "e_stop_placement", "FieldType": "yesno", "Label": "Emergency stop (E-Stop) placement and redundancy verified", "HelpText": "Confirm E-stops are accessible from all expected approach directions and are clearly identified.", "Required": true }, { "Key": "e_stop_locations", "FieldType": "textarea", "Label": "E-Stop locations and notes", "HelpText": "List E-stop locations, any blind spots, and corrective actions if coverage is insufficient." }, { "Key": "guarding_installed", "FieldType": "yesno", "Label": "Physical guarding installed as designed", "HelpText": "Fencing, interlocked gates, panels, and other fixed guards should be present and secure.", "Required": true }, { "Key": "guarding_type", "FieldType": "select", "Label": "Primary guarding type(s)", "HelpText": "Select all that apply (choose the best fit).", "Options": [ { "Value": "fixed_fence", "Label": "Fixed fence or enclosure" }, { "Value": "interlocked_gate", "Label": "Interlocked gate(s)" }, { "Value": "light_curtain", "Label": "Light curtain / laser scanner" }, { "Value": "safety_mats", "Label": "Safety mats / pressure-sensitive" }, { "Value": "collaborative", "Label": "Collaborative robot (cobot) compliant layout" }, { "Value": "other", "Label": "Other" } ] }, { "Key": "guarding_notes", "FieldType": "textarea", "Label": "Guarding notes / deficiencies", "HelpText": "Note missing guards, improper fasteners, or access panel problems." }, { "Key": "safety_interlocks", "FieldType": "yesno", "Label": "Safety interlocks and interlocked gates functionally tested", "HelpText": "Confirm that opening a guarded access point stops hazardous motion and that defeat/override paths are controlled.", "Required": true }, { "Key": "interlock_test_date", "FieldType": "text", "Label": "Interlock test date (most recent)", "HelpText": "Date of the most recent functional test.", "Required": false }, { "Key": "light_curtains_present", "FieldType": "yesno", "Label": "Presence-sensing devices (e.g., light curtains) present where required", "HelpText": "Verify appropriate placement and protected height/settings.", "Required": true }, { "Key": "light_curtain_settings", "FieldType": "textarea", "Label": "Light curtain / scanner settings / notes", "HelpText": "Record sensing grid selection, blanking zones, and alignment concerns." }, { "Key": "sensors_reliability", "FieldType": "scale", "Label": "Confidence in presence-sensing reliability", "HelpText": "1 = Low confidence (frequent faults), 5 = High confidence (recent tests pass)", "Required": false }, { "Key": "cobot_parameters", "FieldType": "yesno", "Label": "Collaborative mode parameters and limits documented (if cobot)", "HelpText": "For cobots, verify speed/force limiting, certified risk assessment, and functional safety measures." }, { "Key": "controls_and_signalling", "FieldType": "yesno", "Label": "Controls, HMI, and warning signals are clear and labeled", "HelpText": "Includes start/stop controls, status lights, audible alarms, and operator instructions." }, { "Key": "maintenance_access", "FieldType": "yesno", "Label": "Maintenance access verified and unblocked", "HelpText": "Check that components needing regular service are reachable without unsafe entry into the work envelope.", "Required": true }, { "Key": "maintenance_obstructions", "FieldType": "textarea", "Label": "Maintenance obstructions / actions required", "HelpText": "Note steps to clear access or add access panels/steps." }, { "Key": "loto_procedures", "FieldType": "yesno", "Label": "Lockout/Tagout (LOTO) procedures defined and posted", "HelpText": "LOTO steps should be documented, available to technicians, and enforced." }, { "Key": "training_required", "FieldType": "yesno", "Label": "Operators and maintenance personnel trained for this cell", "HelpText": "Confirm training completed, including safe entry, E-stop use, and LOTO.", "Required": true }, { "Key": "training_records_location", "FieldType": "text", "Label": "Training records location (file / LMS / folder)", "HelpText": "Where the training evidence is stored." }, { "Key": "commissioning_tests", "FieldType": "checkbox", "Label": "Commissioning functional tests completed (check items)", "HelpText": "Select each test that has been completed during commissioning.", "Options": [ { "Value": "power_on_self_check", "Label": "Power-on and basic self-checks" }, { "Value": "interlock_operation", "Label": "Interlock operation verified" }, { "Value": "estop_response", "Label": "E-stop functional response" }, { "Value": "safety_sensor_test", "Label": "Presence-sensing device test" }, { "Value": "safeguard_override_test", "Label": "Safeguard override/defeat handling" }, { "Value": "recovery_and_restart", "Label": "Recovery and controlled restart test" } ] }, { "Key": "commissioning_comments", "FieldType": "textarea", "Label": "Commissioning comments / open actions", "HelpText": "Record any failing items, temporary mitigations, or corrective actions required before production." }, { "Key": "daily_inspection_items", "FieldType": "checkbox", "Label": "Daily inspection checklist", "HelpText": "Select items verified during today's inspection.", "Options": [ { "Value": "estop_accessible", "Label": "E-stops accessible and functional" }, { "Value": "guards_secure", "Label": "Guards and interlocks secure" }, { "Value": "cables_and_hoses", "Label": "Cables, hoses, and conduits undamaged" }, { "Value": "sensors_clean", "Label": "Sensors, lenses, and light curtains clean and aligned" }, { "Value": "floor_housekeeping", "Label": "Floor clear of trip hazards" }, { "Value": "warning_signs", "Label": "Warning signs visible" }, { "Value": "control_panel_ok", "Label": "Control panel and indicators normal" } ] }, { "Key": "daily_inspection_findings", "FieldType": "textarea", "Label": "Findings from today's inspection", "HelpText": "Describe any defects found and immediate mitigations taken." }, { "Key": "corrective_actions_required", "FieldType": "textarea", "Label": "Corrective actions required", "HelpText": "List corrective actions, target dates, and responsible persons." }, { "Key": "risk_assessment_score", "FieldType": "scale", "Label": "Overall residual risk rating after mitigations", "HelpText": "1 = Low residual risk, 5 = High residual risk (use judgment and refer to formal risk assessment)." }, { "Key": "responsible_engineer", "FieldType": "text", "Label": "Responsible engineer / safety owner", "HelpText": "Name of person responsible for follow-up and approval." }, { "Key": "final_signoff_name", "FieldType": "text", "Label": "Final sign-off (name)", "HelpText": "Person authorizing commissioning or daily release to production.", "Required": false }, { "Key": "final_signoff_role", "FieldType": "text", "Label": "Final sign-off (role)", "HelpText": "Role or title of signing individual." }, { "Key": "final_signoff_date", "FieldType": "text", "Label": "Final sign-off date", "HelpText": "YYYY-MM-DD" } ] }