B&R Automation Discusses Safety Engineering in Automation Today

As machines grow faster and become more adaptive, safety engineering often continues to operate in a parallel world of isolated workflows and fixed constraints. In this interview, Franz Kaufleitner (global product manager safety) and Stefan Schönegger (CTO, ABB Machine Automation division, B&R) share why the time for a shift is right and how Safety+ from B&R aims to close the gap between modern automation and safety engineering.

What brought you into the world of industrial safety, and how does your experience shape what you do today?

Kaufleitner: I've spent the past two decades working in functional safety, seeing firsthand how essential it is for both protecting people and ensuring machines run as productively as possible. Safety engineering has traditionally been seen as a constraint, but I see it as an enabler. My focus is on making safety solutions more intuitive, more efficient, and more adaptable to modern automation needs. And importantly, users are not left alone when it comes to safety: Safety+ is designed to guide them through the workflow with built-in checks and validation support, so safety remains manageable even as machines and projects get more complex.

Schönegger: My background is in industrial automation, controls, and networking. Over the years, I've seen how innovation in standard machine control outpaced safety engineering. That's why Safety+ is so important – it closes that gap, making safety an integral part of modern automation in-stead of an afterthought. Safety should empower engineers, not limit them.

Safety engineering has been evolving for decades. Why is now the right time for a shift like Safety+?

Kaufleitner: Machines are becoming more complex, production cycles are shorter, and the pressure on engineers is increasing. Yet, safety tools have lagged, often requiring separate workflows, limited programming options, and cumbersome validation steps. We saw an opportunity to re-think safety engineering with the same modern approach as standard automation – more open, more flexible, and better integrated.

Schönegger: Another big factor is adaptability. Manufacturing is moving toward smaller batches, customized production, and higher efficiency. But rigid safety implementations don't fit this new reality. With Safety+, we're giving engineers more freedom to build smarter safety functions that enhance – not hinder – machine performance. By making safety a natural extension of automation software, we create more opportunities for efficiency and productivity.

Engineers don't adopt new tools just because they're new. What makes Safety+ a real step forward?

Kaufleitner: The biggest difference is that we've opened up safety engineering. Safety+ removes artificial restrictions that made safety programming slow and rigid. Now, engineers can use an open code base, integrate third-party tools, and take advantage of features like headless applications for CLI interaction. This makes safety programming as efficient as standard control programming, ensuring that machine builders don't have to compromise between safety and agility. At the same time, SafeDesigner+ adds its own independent safety layer which detects unintended code changes and helps prevent accidental modifications from slipping into a validated project – and of course, SafeDesigner+ is TÜV certified.

Schönegger: We also focused on improving machine productivity. Smart safety reactions allow machines to respond to events in a more targeted way, reducing unnecessary stops. For example, in-stead of shutting down an entire production line, Safety+ allows controlled deceleration – keeping machines running safely while avoiding waste and downtime. This is a direct benefit for manufacturers looking to optimize their output.

What are the key advantages for OEMs and end users?

Schönegger: For OEMs, it's about speed and efficiency – developing safety functions as quickly as other automation tasks. Open architecture enables faster iteration, easier collaboration, and more streamlined validation. For end users, it's about reducing downtime and maintenance costs. Auto-mated safety updates and integrated diagnostics mean fewer interruptions and lower total cost of ownership.

Kaufleitner: There's also a space-saving benefit. Faster safety reactions mean machines can operate with smaller clearance zones, making it possible to design more compact production lines. That's a major advantage for manufacturers optimizing factory floor space. Additionally, with improved motion control integration, machine performance is not only safer but also smoother and more predictable, which is a key factor in high-speed production environments.

Five years from now, what role do you see Safety+ playing in industrial automation?

Schönegger: I think we'll see a shift where safety engineering is no longer seen as a separate discipline but fully embedded in automation workflows. The same efficiency gains we've seen in standard control engineering will apply to safety. More advanced diagnostics, predictive safety algorithms, and real-time analytics will further reduce risk while improving machine uptime.

Kaufleitner: Safety+ is setting a new standard – one where safety isn't just about compliance but about smarter, more productive automation. Five years from now, I believe adaptive safety functions will be as common as adaptive machine control, allowing for more flexible and reconfigurable production environments without compromising worker safety.

br-automation.com