Product Overview

Summary: This Automated Systems Troubleshooting Safe Operating Procedure provides a structured, WHS-aligned method for diagnosing and rectifying faults in automated plant and equipment. It protects workers from the unique risks of robotics, conveyors, PLC-controlled machinery and integrated control systems while minimising downtime and maintaining compliance with Australian safety legislation.

Automated systems are now embedded in manufacturing, warehousing, food processing, utilities and many other Australian workplaces. When something goes wrong, there is often pressure to get the line back up quickly, which can lead to unsafe fault-finding practices such as bypassing interlocks, working inside guarded areas, or troubleshooting live equipment without adequate controls. This Automated Systems Troubleshooting SOP sets out a clear, repeatable and defensible process for safely isolating, diagnosing and rectifying faults in PLC-based machinery, robotics, conveyors, automated storage and retrieval systems and other integrated plant.

The procedure is designed to sit alongside your existing WHS management system and lockout/tagout processes, translating legislative duties into day‑to‑day steps that technicians and supervisors can follow. It covers pre-work risk assessment, verification of isolation, safe use of diagnostic software and test equipment, management of software and parameter changes, and structured return-to-service checks. By implementing this SOP, businesses can reduce the risk of serious injury, equipment damage and unintended start-up, while also improving troubleshooting consistency, reducing downtime and supporting compliance with Australian WHS laws, electrical safety requirements and relevant AS/NZS standards.

Key Benefits

• Ensure safe, systematic troubleshooting of automated plant, reducing the risk of electric shock, entanglement and crush injuries.
• Reduce unplanned downtime by providing a clear, step-by-step framework for fault diagnosis and rectification.
• Standardise troubleshooting practices across technicians, contractors and shifts, improving reliability and auditability.
• Demonstrate compliance with WHS legislation, lockout/tagout requirements and relevant Australian Standards for machinery and electrical safety.
• Support effective training and onboarding of maintenance and automation personnel with a documented, easy-to-follow process.

Who is this for?

• Maintenance Technicians
• Automation Engineers
• Electrical Fitters and Mechanics
• Controls and PLC Technicians
• Production Supervisors
• Engineering Managers
• WHS Managers and Advisors
• Operations Managers
• Reliability Engineers
• Facilities and Asset Managers

Hazards Addressed

• Unexpected start-up of automated machinery during troubleshooting
• Exposure to live electrical parts and risk of electric shock or arc flash
• Entanglement, crushing or shearing from moving parts, conveyors and robotics
• Defeating or bypassing guards, interlocks and safety control systems
• Stored energy hazards (pneumatic, hydraulic, mechanical, gravitational and thermal)
• Falls, slips and trips around machinery, access platforms and cable routing
• Data integrity and control system failures caused by uncontrolled software or parameter changes
• Fire or explosion risk from electrical faults or incorrect component replacement

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (PLC, SCADA, interlocks, LOTO, etc.)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Pre-Work Planning and Risk Assessment
• 6.0 Isolation, Lockout/Tagout and Verification of Zero Energy
• 7.0 Safe Access to Automated Systems and Guarded Areas
• 8.0 Troubleshooting Methodology and Escalation Pathways
• 9.0 Use of Diagnostic Tools, Software and Test Equipment
• 10.0 Managing Software Changes, Program Edits and Version Control
• 11.0 Re-energisation, Testing and Return-to-Service Checks
• 12.0 Communication, Handover and Shift Change Requirements
• 13.0 Incident, Near Miss and Fault Trend Reporting
• 14.0 Training, Competency and Authorisation of Personnel
• 15.0 Document Control, Review and Continuous Improvement

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) and equivalent state and territory WHS Regulations – Plant and Electrical Safety
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• AS/NZS 4024 series: Safety of machinery
• AS/NZS 3000:2018 Electrical installations (Wiring Rules)
• AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment
• AS ISO 13849 series: Safety of machinery – Safety-related parts of control systems