Safety upgrade of production lines

Customer: BU Starters, Philips Lighting


BU Starters, is an autonomous business unit of Philips Lighting and is responsible for the development, production, supply chain and worldwide sales of starters. Since safety is key in production, Philips wanted to upgrade the existing production lines to take them to a higher safety level. ImProvia was asked to manage this extensive project and make it a success.


The first production line (U5) was used as starting point. ImProvia made a detailed risk analysis according to NEN-EN-ISO-12100-1 standard. Based on this analysis a basic design and commissioning design was created, both following Customer’s requirements: integration of new safety system with existing machine control system and a controlled production stop with sequence to empty the complete production line.

The project comprised next actions, all delivered by ImProvia:

  • Safety concept & Technical concept;
  • Validation & documentation;
  • Basic design;
  • Support on integrated project planning;
  • Purchasing support (safety PLC, I/O module…);
  • SW Program design;
  • Adaptation of drive circuits (E-plan);
  • Design review;
  • SW program;
  • FAT (offline SW and communication test);
  • Commissioning;
  • SAT;
  • Training and aftercare.


The safety solution designed for the U5 line has been re-applied to other production lines resulting in one uniform safety level. These production lines are still running with high return.

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