Services

Machinery Safety Audits

Prevent costly safety incidents before they happen

Independent machinery safety audits that reduce workplace injuries and improve compliance across multi-site operations, such as retail warehousing and distribution centres.

  • Rapid team mobilisation.
  • OEM-agnostic verification for mixed-equipment facilities.
  • Prioritised recommendations for immediate impact.

Why reactive safety management is costing you more

Machinery safety concept - Workers in a warehouse moving goods with a forklift

Manufacturing and production facilities face a critical safety crisis that’s costing Australian businesses millions:

  • Each year, 139,000 serious injuries cost a median of $14,400 each in NSW
  • 200 Australian workers lost their lives on the job in 2024
  • Safe Work data shows every $1 invested in prevention returns $2.20
  • Mixed-equipment environments create integration blind spots that single-discipline audits miss
  • Regulatory penalties for safety non-compliance continue to escalate

Real-world consequences hitting your bottom line:

  • Unplanned downtime directly impacting production targets
  • Insurance premiums increase with system failures
  • Operators failing to make safety a priority report significantly higher staff turnover
  • Inappropriate interlocks halt entire production lines without warning and reduce productivity

One safety incident can cost more than proactive prevention across your entire facility /network.

Intergrated machinery safety audits that deliver real results

We transform reactive compliance into proactive risk mastery through our proven, multidisciplinary approach, which traditional single-expertise audits cannot deliver.

Your complete safety transformation includes:

✓ Independent cross-disciplinary assessment
Electrical, Mechanical, and Chemical Engineers mapping every hazard integration point

✓ Rapid deployment capability
Team mobilisation within one week – no lengthy procurement delays

✓ OEM-agnostic verification
Vendor-neutral verification eliminates costly manufacturer lock-in

✓ Digital integration platform
Seamlessly integrates with your existing asset management systems

✓ Prioritised action plans
Based on AS4024 hierarchy of controls, focus your budget where it matters most

Proven results: FMCG multinational client success story

The challenge: Following a serious safety incident, a leading multinational FMCG (Fast Moving Consumer Goods) retailer needed urgent visibility of machinery hazards across their vast Australia and New Zealand warehouse network.

Our solution: Advitech’s cross-disciplinary team conducted comprehensive audits across multiple sites, recording findings against existing asset registers and delivering prioritised recommendations by machine type.

The results:

  • Complete risk visibility across the entire warehouse network
  • Targeted hazard elimination with clear implementation priorities
  • Regulatory compliance confidence aligned with WHS obligations
  • Systematic approach enabling consistent safety improvements at scale
  • Empowered decision-making with data-driven insights for senior leadership

Our assessments delivered more than just a list of issues — they provided the client with a clear, prioritised roadmap for action. The client particularly valued our ability to cut through complexity and focus on the most pressing safety issues.

Your four-step safety transformation

Week 1: Rapid assessment deployment

Our certified engineers mobilise quickly to conduct comprehensive on-site audits, mapping mechanical, process, and control hazards across your facilities.

Weeks 2-3: digital integration & analysis

Results are recorded against existing asset registers, identifying equipment that is missing from maintenance programs while creating a data-driven overview of hazards.

Week 4-5: Prioritised action plan

Receive triage results for site calibration and immediate implementation, enabling immediate risk reduction.

Week 6: Identify capital needs and management system adjustments

Collaborate on developing your targeted roadmap with capital and operational recommendations prioritised by risk level and ROI potential.  Our experience can help you identify how to reduce risk so far as is reasonably practicable, while meeting your operational goals.

Differentiation from other approaches

Advitech’s approach uncovers systemic failure modes, removes vendor lock-in, and delivers rapid ROI, addressing common engineering objections to patchwork audits and single-point solutions.

What you get

Traditional approach

Advitech advantage

Assessment scope Single-discipline reviews miss integration risks. A cross-disciplinary team (electrical, mechanical, chemical) identifies all hazards and their interactions.
Vendor flexibility        Locked into manufacturer-specific solutions. OEM-agnostic approach embraces your existing mixed-equipment fleet and unique requirements.
Implementation speed Rigid scheduling. Team mobilised within one week—minimal production disruption.
Financial impact             Reactive fixes after incidents occur. Proactive prevention delivers $2.20 return per $1 invested.
Risk management Compliance-focused. Risk mastery—systematic approach with prioritised action plans.  Giving you a concrete basis for engaging stakeholders and regulators.
Long-term Value  Patchwork solutions create gaps which can become a liability. Full-lifecycle approach from design assessment to 5-year safety audits.

Certified expertise you can trust

Our certified engineers mobilise rapidly to conduct comprehensive on-site audits, mapping mechanical, process, and control hazards across your facilities.

✓ TÜV-certified functional safety engineers
International recognition for safety systems expertise

✓ Rockwell automation partner
System integration capabilities based on the support of a leader in industrial automation.

✓ 50+ SIL2 verifications
Proven track record in Australia’s most demanding safety environments.

✓ ISO 9001 & ISO 45001 certified
Quality and occupational health management systems compliant

✓ Broad expertise:
AS 4024 Machine Safety (ISO 13849), AS 61508, AS 61511 and AS 62061

Man at conveyer belt

Ready to improve your industrial safety?

Don’t wait for the next incident or near miss to force action.  Contact us, and one of our experts will contact you to schedule your independent safety assessment.

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