Project Overview
Advitech helps mining operations stay compliant and avoid costly downtime by managing functional safety across the entire equipment lifecycle. For high-risk systems like powered winders, ongoing safety management protects your people, prevents failures, and keeps operations running smoothly.
After ten years of operation, a mixed-metals mine asked Advitech to review its powered winding systems to ensure they still met the highest safety standards. Although the equipment was installed to comply with safety requirements, the mine wanted peace of mind that its processes continued to deliver the safety performance needed to protect workers and maintain compliance obligations.
Advitech partnered with the client to review their functional safety documentation, identify improvement opportunities, and implement tailored Functional Safety Management Plans (FSMPs) aligned with AS61508 and AS62061.
Advitech’s collaborative approach ensured the client achieved compliance without disrupting operations.
The challenge
- Navigating complex regulatory requirements alongside stringent internal standards set by an international owner.
- Implementing functional safety measures that aren’t part of everyday operations.
- Translating technical standards into practical, plain-language procedures for site teams.
Our solution
Comprehensive Documentation Review
- Assessed all functional safety documentation, including hazard analyses, Safety Integrity Levels (SIL) verification reports, and Original Equipment Manufacturer (OEM) documentation.
- Identified gaps in lifecycle coverage and improvement opportunities in:
- Internal review frequency
- Change management process
- Competence management frameworks
- Validated that hazard analyses and SIL verification reports aligned with lifecycle requirements, ensuring consistency across all functional safety documents.
Tailored Functional Safety Management Plans (FSMPs)
FSMPs outline how each winder is managed throughout its functional safety lifecycle. They form part of the auditable records that show the equipment is designed and operated in line with site risk management requirements. It describes how selected Safety Integrity Levels (SILs) are achieved and support compliance with Australian WHS regulations and standards. Without robust FSMPs, mines are unable to demonstrate that their asset is being managed safely for the risk it presents to its workers, leaving them more exposed to safety incidents.
- Developed FSMPs for each winder, aligned with AS61508 and AS62061.
- Defined lifecycle activities, compliance checkpoints, and responsibilities for ongoing functional safety assurance.
- Incorporated OEM specifications and site-specific operational requirements.
- Included defined verification and validation activities, periodic review cycles, and change management protocols to maintain compliance over time.
Integration and Implementation
- Embedded FSMPs into the client’s governance framework and document control system.
- Ensured traceability, version control and alignment with corporate safety governance requirements.
- Version-controlled FSMPs were integrated for full traceability of safety documents and audit readiness.
Standards applied
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AS61508: Functional Safety of Electrical/Electronic/Programmable Electronic Safety-Related Systems
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AS62061: Safety of Machinery – Functional Safety of Electrical Control Systems
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OEM Specifications and Corporate Governance Requirements
The results
By partnering with Advitech, the mine achieved full compliance, reduced operational risk, and gained a clear, structured safety framework for long-term confidence that their powered winding system is being managed safely and in accordance with industry best practice.
All safety documentation was simplified and centralised, making it easy for teams to access and ensuring day-to-day compliance.
Clear accountability was established for functional safety lifecycle management tasks, so staff know what they need to do to stay safe at work.
Regular safety reviews and clear training processes now keep the system compliant, improve performance, and reduce the risk of costly incidents.
Why Advitech?
With decades of experience across mining, oil & gas, and energy sectors, our Risk and Functional Safety Team brings deep expertise in:
- Functional Safety Management Plans
- High-hazard equipment compliance
- Translating complex standards into practical solutions
Ready to improve your winder safety?
If your safety documentation is unclear or outdated, we’ll make it simple, compliant, and ready for audits, so you can focus on running your operation.
Contact Advitech today to ensure your powered winder safety is robust, compliant, and future-ready.
