Verification & Validation Services
Ensuring Your Machine Safety Systems Meet Design and Functional Safety Standards
At DAK Machine Safety, our Verification and Validation services are designed to confirm that your safeguarding systems not only meet the requirements on paper but also perform reliably in the field. We provide both design verification and onsite validation of your machine safety systems, ensuring full compliance with standards like ISO 13849, IEC 62061, ANSI B11.26 and ANSI Z244.1.
These services are critical in ensuring your risk reduction measures are tested for reliability in engineering, programming, proper installation, and functioning as intended and as required in the risk assessment as to their reliability and function in reducing risk.
Verification Services
Verification involves a comprehensive review of your electrical schematics, safety matrix, and safety PLC logic to ensure the design meets the required Category (Cat.) and Performance Level (PL) in accordance with ISO 13849-1.
Our verification process includes:
- Review of Electrical and Fluid Schematics
We examine your wiring diagrams, component selections, and architecture to confirm proper redundancy, fault detection, and safety category structure. - Evaluation with SISTEMA Software
Using the SISTEMA tool from IFA (Germany), we input all safety-related parts of the control system (SRP/CS) to calculate and verify:- Category (Cat. B–4)
- Performance Level (PL a–e)
- Diagnostic Coverage (DC)
- Mean Time to Dangerous Failure (MTTFd)
- And ensuring each safety function meets the required performance level in design based on the reliability of the components being used, number of actuation, structure and programming.
- Safety Matrix Development
We cross-reference each input, with their respective outputs in your safety matrix with your schematics, whether it is possible of being bypassed, and PLC logic to verify that all intended safety functions are correctly designed and implemented. - PLC Safety Code Review
Our engineers review the safety controller programming to ensure proper structure, reset logic, interlocking, zone management, and error handling are in line with your risk reduction strategy.
Validation Services
Field Visual, Functional and Abnormal operation. Test, Validate and Document
Validation confirms that the installed safety systems functions and control systems operate as defined in the original design. We follow ISO 13849-2 and ANSI B11.26 validation principles, executing a structured process that includes:
- Visual Inspection
Our engineers inspect all safeguarding devices (light curtains, Fixed guard, lockout procedures, Alternative Methods, Interlocks, scanners, e-stops, two-hand controls, etc.) to confirm proper installation, compliance with the environmental requirements and processed material, mechanical robustness and any future inspections that maybe needed. - Functional Testing
Devices are activated to confirm correct behavior of the control system. We check:- Emergency stop response
- Safety zone control
- Interlock behavior
- Reset and restart logic
- Manual/auto mode transitions
- Abnormal Tests and Forced Fault Injection
We simulate failures (e.g., short circuits, open wires, sensor misalignments) to validate:- Redundancy and fault detection
- Diagnostic capabilities of the system
- Internal monitoring and feedback mechanisms
- Proper handling of unsafe conditions by the safety PLC and controller
Validation Report
A complete write-up includes:
- Schematics reviewed
- Validation procedure and steps performed
- Photos and device IDs
- Pass/fail criteria
- Deviations or corrective actions
- Final compliance statement
- Major issues that need to be addressed
Standards We Validate Against
DAK validates your safety systems against applicable standards, including:
- ISO 13849-2 – Validation of safety functions
- IEC 62061 – Functional safety of control systems
- ANSI B11.19 / B11.26 – Performance and validation of safeguarding
Why Verification & Validation Matter
Prevents false sense of safety from incomplete or non-functioning safety devices
Identifies wiring, programming, or design flaws before and ensures the line is safe to place in operation after a major upgrade or new installation.
Partner with DAK for End-to-End Safety Assurance
DAK’s Verification & Validation services can be provided independently or as part of a full project—including risk assessment, engineering design, turnkey integration, and operator training.