The Gold Standard for Aluminum Safety

Implementing functional safety upgrades across a global aluminum manufacturing operation.

A global aluminum extrusion manufacturer set out to evaluate and improve machine safety across more than 20 facilities. The initiative focused on identifying risks and implementing machine safety controls that would better protect employees while supporting safe, efficient production.

The Problem

Safety is a basic need, not only for the health of workers, but also for the efficiency and sustainability of manufacturing plants. Our client set out to systematically identify and reduce machine safety risks across an entire aluminum production facility. The goal was to establish a consistent approach to functional safety, address hazards across multiple machines and work areas, and improve protection for employees without sacrificing production performance.

The Solution

The project began with a comprehensive machine safety risk assessment. This consultative process evaluated equipment functions, operator interaction, foreseeable misuse, operating conditions, and hazards throughout each machine’s lifecycle. The findings created a roadmap for remediation and helped define the specific safety controls, guarding, and sensing technologies required across the facility.

For this project, Rockwell Automation completed the initial assessment and Concept Systems used those findings to engineer and implement the required upgrades. Concept selected and procured the necessary hardware, then integrated, configured, and tested safety enhancements across ovens, conveyors, saws, extruders, stretchers, and other equipment throughout the aluminum line.

The assessment identified a range of hazards across the equipment and operating environment, including:

• Mechanical and electrical hazards
• Thermal, noise, and vibration hazards
• Ergonomic and material-related risks
• Slips, trips, and falls
• Environmental and combined hazards

Each identified hazard was evaluated based on risk, helping prioritize the required safety improvements. The findings were consolidated into a single assessment that Concept used to begin engineering and remediation.

Today, this same consultative approach is reflected in Concept Systems’ Safety Risk Assessments, which identify hazards, prioritize risk-reduction opportunities, and define specific remediation work that can move directly into engineering and implementation.

Examples of Machine Safety Control & Upgrades:

Concept installed Rockwell Automation guard-locking devices across 26 work cells, along with light curtains and area scanners to control access to hazardous areas and help prevent equipment motion while personnel were exposed to risk.

KEYENCE safety laser scanners were also installed at the head stock and tail stock of the extrusion process to detect personnel or objects in hazardous areas before the aluminum stretching sequence could proceed.

After implementation, Rockwell Automation returned to validate the safety integrations and confirm that the designed safety functions performed as intended. Concept also provided updated electrical drawings and full documentation to support long-term maintenance and future modifications.

The Results

Concept ensured that the safety controls implementations had minimal impact on production during the install. As soon as the full install and training were complete, plant production returned to top operating capacity.

• Reduced identified machine safety risks across the aluminum production line
• Minimized production disruption during implementation
• Improved maintainability with updated electrical schematics and documentation
• Integrated modern safety technologies including guard locking, light curtains, and area scanners
• Supported safer access and operating procedures throughout the facility

Learn More About Our Safety Controls Capabilities

Project Details