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Redesign a workstation for human–robot collaboration as an application-engineering project, not as a robot purchase. Start by mapping every task, person, workpiece, tool, access route and abnormal condition. Then perform a risk assessment, decide whether people and the robot truly need shared space or a shared workpiece, select safeguards for the possible contact situations, and validate the complete cell through its operating life.
A collaborative-rated robot is not automatically safe beside a worker. The end-effector, payload, workpiece edges, fixtures, controls, layout, nearby equipment, safeguarding and procedures determine the risk. The current ISO framework separates robot safety from application integration: ISO 10218-1:2025 addresses the industrial robot as a machine, while ISO 10218-2:2025 addresses integration and the cell through design, commissioning, operation, maintenance, decommissioning and disposal. ISO/TS 15066:2016 supplements both parts for collaborative applications and was reviewed and confirmed in 2022.
Start with the work, not the robot
Before moving a bench or selecting a robot, document how the job is actually done. A workstation often has several different “operators”: production workers, material handlers, setup technicians, programmers, maintenance staff, quality personnel and supervisors. Each may enter a different area, handle a different tool or work under a different control mode. A layout that works for normal production can be unsafe during setup, fault recovery or cleaning.
Build a task and people map
For every product variant and process step, record:
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- What the person does, including lifting, positioning, inspection, fastening, teaching, replenishing material and clearing scrap.
- What the robot does, including travel, gripping, dispensing, loading, unloading and waiting states.
- Where each action occurs and which side of the workstation the person approaches from.
- Which workpieces, fixtures, end-effectors and consumables are used, including variants that change mass, geometry or sharp edges.
- Normal production, startup, shutdown, changeover, programming, testing, jam clearing, cleaning, maintenance and emergency activities.
- Every route by which a person can enter the robot’s operating, restricted or safeguarded space, intentionally or accidentally.
Observe the process rather than relying only on a standard operating procedure. Note reaches across the robot, handoffs that require two people, blocked sight lines, temporary carts, floor-level storage and any step workers already bypass because the designed sequence is inconvenient. These observations become design inputs and later validation tests.
Separate operating modes
Write a mode matrix for automatic production, manual load or unload, teach and programming, setup, maintenance, fault recovery and emergency stop. For each mode, specify who may enter, what motion is enabled, what enabling device or reduced-speed control is required, and how the cell returns to a verified safe state. Do not assume that a safeguard used in automatic mode remains adequate when a technician has to reach into the cell.
Perform the risk assessment before selecting a collaboration concept
OSHA’s Technical Manual states: “At each stage of development of the robot application (design, manufacturing, integrating, operating, and maintaining), a risk assessment should be performed.” Treat that as a continuing activity, not a commissioning form completed once. OSHA’s listed factors include tasks, startup and programming, the environment, location, worker error, maintenance, system malfunction, normal operation, emergencies and worker duties. Involve the people who perform those tasks; they know where the planned sequence differs from reality.
Assess the whole integrated application
Define the boundaries of the assessment broadly enough to include:
- The robot arm and controller, including reachable and restricted areas.
- Every end-effector, tool changer, gripper, cutter, dispenser, vacuum circuit and stored-energy source.
- The workpiece, fixture and pallets, including pinch points, projections, hot surfaces, sharp edges and unexpected movement.
- Conveyors, presses, machine tools, feeders, guarding, safety scanners, interlocks and other equipment that can interact with the robot.
- Operator stations, material presentation, aisles, platforms, ladders, egress routes and spaces where a person could become trapped.
- Software, recipes, networked commands, mode selection, restart behavior and loss of power or communications.
For each hazard, describe the initiating event, the person exposed, the possible injury mechanism, existing controls and the evidence required to verify the control. Reassess when the workpiece, tooling, robot program, process speed, nearby equipment or environment changes.
Ask OSHA’s application questions literally
These questions help determine whether a shared workspace is necessary:
- “Is the presence of a person integral to the application?”
- “Do the robot and person have to share a workstation?”
- “Do the robot system and person have to work on the same workpiece simultaneously?”
- “Does the person need to be in physical contact with the robot, end-effector, or workpiece while the robot system is in motion?”
A “no” answer can justify physical separation, interlocked access or a different material-flow design. A “yes” answer does not approve collaboration; it identifies a condition that must be controlled and validated.
Choose the least complicated arrangement that meets the task
Human–robot collaboration is not one layout or one safety function. Compare alternatives against the same task scenarios and evidence. Often the safest redesign is to remove the need for simultaneous access rather than make simultaneous access more sophisticated.
Option 1: Separate the person and robot
Use a guarded robot cell, interlocked gate or other physical separation when the person can load, unload, inspect or replenish from outside the motion area. This arrangement is appropriate when the tasks do not require simultaneous contact and when material flow can be redesigned with fixtures, conveyors or external staging. Verify that an operator cannot reach through, climb over or become trapped behind the safeguard.
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Option 2: Shared space at different times
Allow a person to enter only when the robot is stopped and the safety system has confirmed the required state. A monitored stop, gate interlock or presence-sensing arrangement may support this concept, but the exact combination depends on the assessed hazards. Define restart controls so that closing a gate or leaving the space cannot by itself create an unexpected restart.
Option 3: Shared space during selected operations
Use speed and separation monitoring, power and force limiting, or another suitable combination when a person must work near a moving robot. The assessment must consider the robot, end-effector and workpiece as contact bodies. A rounded arm can still present a hazard through a sharp tool, a projecting fixture or a heavy moving part. Set operating limits and protective responses for the actual task, not for an unloaded demonstration.
Option 4: Shared workpiece
When a person and robot handle the same workpiece, analyze every handoff and possible loss of grip. Determine whether the robot can stop without dropping, ejecting or pinching the part, and whether the person can withdraw without passing through the robot’s path. Fixtures should make the intended grasp and release states obvious; avoid requiring a worker to hold a part in an uncertain position while waiting for motion.
Compare redesign alternatives with one evidence framework
Use a written comparison rather than choosing by appearance, marketing terminology or a demonstration cycle. Score each candidate against the same normal and non-routine scenarios.
| Comparison axis | Questions to answer | Evidence to collect |
|---|---|---|
| Task and workflow fit | Can each party perform its assigned steps without awkward handoffs, blocked work or unnecessary simultaneous access? | Observed sequence, cycle logic, changeover steps and worker feedback |
| Access and ergonomics | Can workers reach, see and manipulate the task safely? Is there clearance for operation, setup and maintenance? | Site-specific ergonomic review, reach and posture observations, access trials |
| Robot and workpiece space | Where are operating, restricted and safeguarded spaces? Do they overlap machines, aisles or escape routes? | Reach study, layout drawing, clearance checks and trapped-person analysis |
| Contact and safety functions | Is contact expected while moving? Are selected speed-and-separation or power-and-force functions suitable for that contact situation? | Risk assessment, safety-function specifications and validation results |
| Safeguarding and visibility | Do protective devices control access without creating new hazards or hiding the task from the operator? | Sensor coverage, interlock tests, visibility review and fault-response tests |
| Change and lifecycle management | What happens when the workpiece, end-effector, process, software or environment changes? | Change-control triggers, reassessment records, training updates and revalidation plan |
These axes are a decision framework, not universal dimensions or a substitute for a site-specific assessment. The available official guidance does not establish a single safe reach, speed, force or separation distance for every workstation.
Design the physical layout around access and foreseeable errors
Map operating, restricted and safeguarded spaces
Draw the robot’s maximum reach with each tool and payload, then add the workpiece and any possible dropped or ejected item. Mark restricted areas created by fixtures, nearby machines and pinch points. Mark safeguarded boundaries, access doors, scanners and emergency devices. Compare this map with operator routes, forklift paths, material carts and maintenance access. A person should not have to cross an unprotected robot path to reach controls, consumables or an escape route.
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Make the boundary understandable
Workers should be able to tell where the collaborative or safeguarded space begins, what motion is possible and which controls govern entry. Use consistent physical cues, clear status indication and controls located where the user can see the cell. Do not rely on floor tape alone to prevent entry into a hazardous space. Ensure that lighting, glare, dust and stored materials cannot defeat presence sensing or hide a person from view.
Design the workpiece presentation
Present parts at a stable height and orientation that avoids reaching across moving links. Provide a defined location for rejected parts, empty bins and tools so that temporary storage does not enter the robot envelope. If the process includes sharp, hot, heavy or flexible parts, control those hazards independently of robot speed or force limits. A power-and-force-limited robot does not make a hot workpiece or a cutting edge harmless.
Provide maintenance and setup clearance
Allow technicians to access controllers, cable routes, grippers, sensors, lubrication points and fixtures without standing in an unrecognized trap space. Identify how a person can enter, exit and summon help. If a task requires holding a device or maintaining visual contact, design the control location and access path accordingly. The dimensions must be established for the actual equipment and jurisdiction; no generic workstation measurement replaces that evaluation.
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Select and combine safeguards for the assessed contact conditions
OSHA discusses speed and separation monitoring, power and force limiting, monitored stops used with other collaborative methods, protective stops, force and speed limiting, and passive measures such as rounding edges and removing projections. These are options, not a universal recipe. The possible contact situations determine which functions and performance levels are appropriate.
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Speed and separation monitoring
Use this concept when the robot can slow or stop before a person reaches a hazardous distance. Define how the system detects a person, how distance is measured, what happens during sensor faults and how the robot resumes motion. Analyze the fastest approach route, robot stopping time, payload, tool geometry and any area a scanner cannot see. A sensor that covers normal operator entry may not cover a maintenance worker approaching from behind.
Power and force limiting
Use force and power limits only after evaluating all contact surfaces and credible impacts. The assessment must include the arm, tool, workpiece, fixture and any stored or moving material. Passive design helps: round edges, eliminate projections, reduce pinch opportunities and constrain motion where practical. Verify the actual integrated application; a setting in a controller is not proof that every configuration is within an acceptable limit.
Monitored and protective stops
A monitored stop can permit a person to perform a task while robot motion is held, but it must be combined with controls that prevent unexpected restart and address other energy sources. A protective stop should respond to the detected condition and leave the system in a state from which a trained person can recover safely. Test stops with realistic payloads, programs, sensor faults and power interruptions.
Physical and passive safeguards
Guards, interlocked doors, fixed barriers, restricted openings and carefully positioned controls remain useful even in a collaborative cell. Reduce risk at the source by removing sharp projections, enclosing hazardous tooling, limiting stored energy and choosing fixtures that prevent unintended movement. Safeguards must not introduce new pinch points, obstruct emergency egress or encourage workers to bypass them.
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Many robot incidents occur during non-routine activities such as programming, maintenance, testing, setup or adjustment. Treat those activities as designed operating modes with their own assessment, authorization and instructions.
Setup and programming
- Define who may select teach or setup mode and how access is authorized.
- Use reduced-speed or other controlled-motion functions required by the assessed task.
- Provide an enabling device that must be held in the required state, and test what happens when it is released or squeezed.
- Make the selected mode visible at the point of control and prevent remote commands from defeating local safeguards.
- Require a deliberate, verified restart after program edits, gate openings or protective stops.
Maintenance and troubleshooting
- Identify electrical, pneumatic, hydraulic, thermal, gravitational and stored mechanical energy.
- Provide isolation and verification steps before a person enters or reaches into the cell.
- Define how to support a suspended arm, fixture or workpiece if braking or power is lost.
- Keep diagnostic access outside the hazard area where possible; otherwise provide controlled entry and communication.
- Record changes to software, tooling, safety devices and parameters, and specify when they trigger reassessment.
Faults and emergencies
Test sensor blockage, loss of communication, unexpected object detection, gripper failure, dropped parts, power restoration, emergency stop, gate opening and controller restart. Decide who may clear a fault and what inspection is required before automatic operation resumes. An emergency stop is not a substitute for guarding, isolation or a safe recovery procedure.
Apply the current standards at the correct level
ISO 10218-1:2025
ISO 10218-1:2025 is the third edition, published in February 2025. It addresses safety requirements for industrial robots as machines. ISO identifies integration and application requirements in Part 2. Conformance of a robot alone does not establish that a workstation, tool, process or cell is safe.
ISO 10218-2:2025
ISO 10218-2:2025 is the second edition, published in February 2025. It covers integration of industrial robot applications and cells, including design, commissioning, operation, maintenance, decommissioning and disposal. Its lifecycle scope is a useful reminder to include handover records, training, change control and end-of-life work in the redesign.
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- Real-Time Leader-Follower Functionality – New real-time tracking allows the leader arm to follow the follower arm, enabling human intervention and correction during reinforcement learning (RL) training. Perfect for hands-on AI robotics development and research
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ISO/TS 15066:2016
ISO/TS 15066:2016 addresses collaborative industrial robot systems and the work environment and supplements ISO 10218-1 and ISO 10218-2. ISO reports that it was reviewed and confirmed in 2022, so this edition remains current. Use it as collaborative-application guidance alongside the current ISO 10218 editions, not as a stand-alone approval of a particular cell.
OSHA and local legal requirements
OSHA’s robotics overview says there are currently no specific OSHA standards for the robotics industry. That does not remove occupational-safety duties. OSHA’s standards index also states that the consensus standards listed there are not OSHA regulations. Determine the requirements that apply to the facility, state or country, machinery, electrical installation, workplace and industry, and document how the integrated application meets them.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Commission, validate and hand over the cell
Validation should demonstrate that the robot, end-effector, workpiece, safeguards, controls, layout and procedures work together as intended. ISO 10218-2:2025 includes commissioning and lifecycle operation; OSHA discusses verification at site acceptance in its integration guidance.
- Freeze the assessed configuration. Record robot model, payload, tools, fixtures, software revision, safety parameters, safeguards and workpiece variants.
- Verify installation. Check barrier locations, openings, scanner fields, interlocks, emergency devices, control-panel access, grounding and energy isolation points.
- Test each safety function. Trigger gate opening, presence detection, protective stop, monitored stop, enabling-device release, emergency stop, sensor failure and communication loss. Confirm the defined safe response and reset behavior.
- Test realistic production states. Run the largest and smallest parts, each tool, normal and worst-case payload, full speed where permitted, empty grippers, misaligned parts and credible dropped-part conditions.
- Test non-routine work. Have authorized personnel perform setup, program adjustment, jam clearing, cleaning and maintenance using the written procedures. Correct any workaround or unexpected reach.
- Document evidence. Keep risk assessments, drawings, safety-function calculations or test records, software backups, inspection results, training records, operating instructions and open actions.
- Obtain acceptance. Have responsible engineering, operations, maintenance and safety personnel review the evidence and formally accept the cell before production release.
Operate the redesign as a controlled system
Train by task and mode
Training should match authorization: ordinary operators need production, stop and abnormal-condition instructions; setup personnel need controlled motion and recovery skills; programmers need change-control and validation duties; maintenance personnel need isolation, stored-energy and re-entry procedures. Refresh training when the robot, workpiece, software, safeguards or work organization changes.
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Define changes that automatically reopen the assessment: a new end-effector, payload, product geometry, fixture, cycle speed, software revision, sensor relocation, nearby-machine change, floor-plan change or environmental condition such as dust, glare or temperature. Require a documented review before the altered cell returns to production.
Audit real behavior
Observe whether workers bypass scanners, leave gates open, reach around barriers, disable alarms or store materials inside the envelope. Treat these findings as design failures to correct, not merely as rule violations. Review near misses, nuisance stops, ergonomic complaints and maintenance delays because each can reveal an unsafe incentive in the layout or procedure.
Common redesign mistakes and their corrections
| Mistake | Why it fails | Correction |
|---|---|---|
| Assuming a collaborative robot is safe by itself | The tool, workpiece, fixture and environment can create hazards the arm rating does not cover. | Assess and validate the complete integrated application. |
| Choosing a safety mode before mapping the task | The selected function may not address the actual contact or access scenario. | Define who must be where, when and in contact with what, then select controls. |
| Designing only for automatic production | Programming, maintenance, testing and recovery often require different access and motion. | Create separate operating modes and test each one. |
| Using floor markings as the primary safeguard | Paint does not stop entry, detect a person or prevent reach-through. | Use engineered barriers, interlocks, presence sensing or other controls justified by the assessment. |
| Copying a clearance or force value from another cell | Robot reach, payload, tool geometry, stopping time and worker approach differ. | Establish site- and application-specific values and verify them. |
| Ignoring temporary materials and variants | Carts, bins, new parts and alternate tools can change reach, visibility and impact hazards. | Include variants in the assessment and define change triggers. |
| Treating a standard as a legal certificate | Consensus standards are not automatically regulations or complete jurisdictional compliance. | Check applicable law and document how the integrated design satisfies it. |
A practical redesign checklist
- All worker roles, routes and non-routine tasks are mapped.
- Robot, tool, workpiece, fixture, nearby equipment and stored energy are included in the hazard analysis.
- The need for shared space and simultaneous work on a workpiece is explicitly answered.
- Operating, restricted and safeguarded spaces are shown on a current layout.
- Each safety function has a defined trigger, safe response, reset behavior and test record.
- Setup, programming, maintenance, fault recovery and emergency access are designed, not improvised.
- Ergonomic reach, posture, visibility and material presentation are evaluated at the actual site.
- Workpiece and end-effector variants have been tested or controlled.
- Training, operating procedures, isolation instructions and change-control records are complete.
- Responsible personnel have reviewed validation evidence and accepted the cell for operation.
What a successful redesign delivers
The outcome is not simply a robot placed closer to a person. It is a documented cell in which the work sequence, access, safeguards, controls and lifecycle procedures agree. The worker knows when shared space is permitted, the robot’s possible motions are bounded by the assessed task, and setup or maintenance does not depend on informal workarounds. The design can also be re-evaluated when a tool, part, program or surrounding process changes.
Frequently Asked Questions
Can I make an existing workstation collaborative by changing the robot’s speed limit?
No. Speed is only one input to an application-specific assessment. Re-evaluate the end-effector, workpiece, fixtures, stopping behavior, access routes, safeguards, operating modes and foreseeable non-routine tasks, then validate the complete modified cell.
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They address different levels. Part 1 covers the industrial robot as a machine; Part 2 covers integration and the application or cell through its lifecycle. Use the editions relevant to your equipment and jurisdiction, together with collaborative guidance where applicable.
What should change-control cover after commissioning?
At minimum, define review triggers for new workpieces, end-effectors, payloads, fixtures, programs, speeds, sensors, nearby equipment, layout and environmental conditions. Require reassessment and, where needed, revalidation before production resumes.
Is a consensus robot-safety standard an OSHA regulation?
No. OSHA states that the consensus standards listed on its robotics standards page are not OSHA regulations. Determine all legal and occupational-safety requirements applicable to your facility and location.
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