Methodology for Safety and Risk Assessment in Learning Factories: Enhancing Evaluation and Skill Development in Industry 4.0 Chapter in Scopus uri icon

abstract

  • This paper presents the implementation of a safety and risk assessment methodology developed during a Capstone project in the course Design and Development of Mechatronics Systems at Tec's Smart Factory. Using a challenge-based learning approach co-created with industry partner Rockwell Automation, students were tasked with integrating a manufacturing process for part production, with the goal of future automation. The challenge involved the integration of various industrial equipment, including conveyors, storage units, industrial Fanuc robots, Haas MiniMill CNC machines, industrial sensors, actuators, and Allen Bradley PLCs. To address safety concerns, a methodology was introduced to evaluate risks associated with industrial equipment and worker interaction. This approach integrated two key safety standards: IEC 61511, which focuses on hardware safety, and ISO 13849, which outlines safety procedures and risk analysis in manufacturing environments. A safety assessment of the Smart Factory was conducted both before and after the methodology's implementation. The project enabled students to develop practical and consultancy skills while demonstrating advanced problem-solving and technology literacy-essential competencies for the Industry 4.0 era. Finally, students delivered improved safety solutions in Tec¿s Smart Factory compared to previous lab experiences, underscoring the educational and industrial significance of the methodology. © The Author(s), under exclusive license to Springer Nature Switzerland AG 2026.

publication date

  • January 1, 2026