Price: $3,398.00

Length: 4 Days
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Tonex Safety Engineering Training Bootcamp

Having the expertise of a safety engineer in your organization can prove to be a valuable component of any environment, health and safety department (EHS).

Safety engineers control risk to your company in ways that safety leaders and managers cannot. Their understanding of systems and operations is broader because they look at deeper level components and consider the “big picture” before implementing their ideas.

In addition, safety engineers have an educational background in engineering and apply those same principles to create a safe work environment. They have a strong comprehension of science, math, and design to help them develop effective systems that continue working even when other parts fail.

Necessary skills for a safety engineer include:

  • Excellent communication and responsiveness
  • Computer skills
  • Teamwork
  • Accuracy
  • Knowledge of compliance requirements, personal protective equipment and training requirements
  • A strong desire to work with and improve the existing safety systems in a company

Also, safety engineers may take additional professional development courses from highly acclaimed governing bodies like the Safety and Health Institute or the American Society of Safety Engineers.

Safety engineering design concepts include all environmental aspects of the workplace such as lighting, noise levels, atmospheric contaminants, ambient and localized temperature extremes, slip resistance of flooring materials, emergency escape routes and fire suppression and alarm systems.

Safety engineering also is the key component for eliminating hazards that would otherwise be controlled by either administrative controls or use of personal protective equipment as a barrier between a hazard and a worker.

These engineered safeguards include machine guards, selection of less hazardous equipment, development of maintenance schedules to ensure equipment safety, audit and inspection procedures, selection of safer tools, safety review of new equipment, employee maintenance training, safe design of the flow of material and people through a facility and risk analysis for both possible man-made and natural incidents.

Additionally, engineered safety includes fail safe process equipment, fault-tolerant equipment, fire safety features and enclosed hazardous systems that prevent exposure to both workers and the environment.

Safety engineering and reliability engineering have much in common but the two are not the same. Probabilistic risk assessment has created a close relationship between safety and reliability.

Component reliability, generally defined in terms of component failure rate, and external event probability are both used in quantitative safety assessment methods such as FTA. Related probabilistic methods are used to determine system Mean Time Between Failure (MTBF), system availability, or probability of mission success or failure.

Most experts in this area agree that safety factors should be employed early in a design process. This is where safety engineers can provide insight into how people will interface with the equipment and facility design.

Safety design early on ensures not only safe design for people, but also, a safe operational concept that will carry over into capabilities for the facility to handle industrial and non-industrial incidents and minimize the cause-effect.

Tonex Safety Engineering Training Bootcamp Course by Tonex

Tonex safety engineering training bootcamp is a comprehensive training package that covers all the machinery safety regulations, training, standard requirements, and risk assessment.

This intensive hands-on workshop will train you to:

  • Stay safe and healthy and prevent any incident
  • Act effectively, properly, and safely if incident occurs
  • Analyze the incident and identify the causes of the accident
  • Reduce the risk of accidents
  • To eliminate the causes of the incident and avoid it from reoccurring

The TONEX Safety Engineering Training Bootcamp is conducted as an interactive presentation in which all the participants are actively involved in group activities, hands-on workshops, and case study practices. The seminar includes 10 sections in which both lectures and workshops are covered. Each section finishes with a hands-on workshop that allows participants to practice and strengthen what they are thought in that section through coaching our instructors. The bootcamp ends with an open book exam led to attaining certification.

In addition to the safety and risk assessment process training, this seminar will provide CE marketing training. CE marketing training is the last step of the compliance evaluation process to the EU’s Machinery Directive. Such process includes:

  • Risk analysis of the machinery through its lifecycle
  • Achieving safety millstones by design and production
  • Applying best practice to guarantee the machinery safety
  • Gathering information in regards to design, test, and construction process and all the measures required for the machine to conform with the key requirements of all the associated product safety directives in a technical file, and be kept for 10 years
  • Asserting the machine’s compliance with product safety regulations (Declaration of Conformity), accompanying the machine to the customers
  • Preparation an Operator’s Manual for the customer, in their own language


Tonex Safety Engineering Training Bootcamp is a 4-day hands-on seminar designed for managers, engineers, scientists, technicians, and all individuals who are involved with running machinery at the manufacturing companies. Some portion of this training is required by law for whoever working on site, with or around machinery.

Training Objectives

Upon the completion of this bootcamp, attendees are able to:

  • Define machinery safety and its specifications
  • Identify what is hazard and what is not
  • Determine the potential risks of all the machinery they run
  • Avoid dangers and harm caused by machinery
  • Explain and discuss US and international standards relevant to machinery, including ISO, OSHA, CSA, CE, ANSI, IEC
  • Handle and manage incidents when they happen
  • Report the incident properly to their managers
  • Understand their responsibilities and duties regarding safety of machinery
  • Implement machines guarding, PPE, machine noise, warning labels, lockout/tagout, emergency stops, interlocks, light curtains, and other safety protocols to keep their own and others safe at workplace
  • Understand the risk analysis process
  • Apply risk reduction techniques
  • Incorporate risk reduction from the beginning
  • Understand and articulate the difference between risk assessment and risk reduction processes
  • Recognize and consider dangers during the risk assessment procedure
  • Create and develop risk assessment templates based on the situation
  • Execute risk assessment procedure
  • Measure risk reduction
  • Evaluate the risk level and the amount of required risk reduction
  • Document risk assessments properly and effectively
  • Choose protective measures corresponding with risk level
  • Identify difference between zero risk and tolerable risk
  • Measure tolerable risk
  • Understand CE marketing process
  • Conduct all steps of the CE marketing process

Course Outline

Day 1

Section 1- Introduction to Safety

  • Basics of safety
  • Why do we need to consider machinery safety
  • What are the applicable safety legislation
  • Responsibilities of mangers and executives
  • Safety Management Systems

Section 2- Safety Legislation

  • Local and federal legislations in regards to:
    • Design machinery and work equipment
    • Construction machinery and work equipment
    • Maintenance machinery and work equipment
  • Equipment and instruments regulations
  • Occupational Health and Safety regulations relevant to machinery, such as ergonomics, noise, vibration, and chemical agents
  • CSA Z432-04 – Safeguarding of Machinery – Occupational Health and Safety
    CSA Z434-03 – Industrial Robots and Robot Systems – General Safety Requirements
    CSA Z460-05 – Control of Hazardous Energy – Lockout and Other Methods
  • NOM-004-STPS-1999 – Protection Systems and Safety Devices for Machinery and Equipment Used in the Workplace
  • OSHA requirements training
    • Machine guarding (Support O)
    • Personal Protective Equipment (Support I)
    • Electrical equipment and electrical hazards (Support S)
    • Machine noise
    • Warning lables
    • ANSI Z535.4
    • Lockout/tagout (Section 147)
    • Permit Required Confined Spaces (Section 146)
    • Specification for Accident Prevention Sign & Tags (Section 145)
    • Emergency stops
    • Interlocks
    • Light curtains
  • Requirements to sell machinery in the market or put it into service
    • CE Marketing

Day 2

Section 3- Risk Assessment

  • Some real-life cases
  • Risk assessment ISO 12100 and best practice
  • ANSI and ISO requirements differences
  • Zero risk vs. tolerable risk
  • Measuring tolerable risk
  • Techniques of risk assessment
  • Risk assessment procedure, step by step from the beginning to completion
  • How to correctly analyze an incident :
    • severity
    • probability
    • frequency
    • ability to prevent
  • Other relevant machine standards applicable in risk assessment procedure
  • Hazard reduction methods
  • Risk reduction techniques, after completing risk assessment
  • Risk reduction measures
  • Difference between risk reduction and risk assessment processes
  • Risk Level and required level of risk reduction
  • Proper protective measures corresponding with risk level
  • Consider and apply risk reduction from the beginning
  • Effectiveness of awareness tools
  • Effectiveness of administrative controls
  • Effectiveness of PPE
  • Workshop 1: case studies and real examples of risk assessment
  • Workshop 2: Root Cause Analysis for a real example

Section 4- Mechanical Guarding

  • Some terminology
  • Guard classification
  • Identifying machine/process
  • Collecting proper information
  • Gather proper personnel
  • Identifying hazardous area(s)
  • Set back distance of barrier Guards
  • Barrier height and distance vs. height of hazard
  • Safe mounting distance
  • Standards requirements, US and international
  • ANSI B11.0 (2010) – Safety of Machinery – General Requirements and Risk Assessment
  • ANSI B11.19 (2010) – Performance Standard for Safeguarding
  • ANSI Z535.4 (2011)  – Product Safety Signs and Labels
  • ANSI Z535.6 (2011) – Product Safety Information in Product Manuals
  • ISO 13857 and safety distances analysis

Section 5- Safety Factors and Machineries

  • An overview to elements, requirements, and applications of safety
  • Features and usage
  • Pros and cons
  • Supplemental safety measures
  • Control systems associated with safety

Day 3

Section 6- Electrical Safety

  • IEC 60204-1; for electrical equipment of machines
  • Thorough design considerations
  • How to use and maintain electrical machines and stay safe
  • NFPA 79 – Electrical Standards for Industrial Machines
  • OSHA Regulations for Electrical Safety – CFR 1910 Subpart S
    • Subpart S – Electrical equipment and electrical hazards.
    • Section 147 -Control of Hazardous Energy (Lockout/Tagout)
    • Section 145 – Specification for Accident Prevention Sign & Tags
  • National Electric Code (NEC)

 Section 7- Control Systems Safety

  • ISO 13849 standard requirements
  • Requirement, design, and validation of Functional safety control systems
  • Architecture selection and practical examples of category realization
  • Software specifications and usage
  • Techniques and methods of verification and validation
  • IEC 62061 review
  • Workshop: Practicing PL and SIL validations case studies

Day 4

Section 8- Pressurized Fluid Systems Safety

  • ISO 4413 and ISO 4414 standards, relevant to hydraulic and pneumatic respectively
  • How to apply hydraulic and pneumatic systems safely
  • Hydraulic and pneumatic elements
  • Compliance of the fluid control systems safety parts to ISO 13849-1
  • Workshop: Case studies of hydraulic and pneumatic safety systems

Section 9- Practicing a real scenario- Performing a complete procedure on a scenario from risk assessment to after even actions

Section 10- “Open Book” Tonex Examination

Tonex Safety Engineering Training Bootcamp

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