As industries across the world rapidly transition toward automation, robotics, and smart manufacturing ecosystems, machine safety has emerged as one of the most critical pillars for achieving sustainable productivity, operational excellence, and workforce protection. Today’s modern manufacturing environment is no longer driven only by speed and output, but also by the ability to create safe, intelligent, and globally compliant production systems that can adapt to the changing industrial landscape.
In this exclusive interaction, insights by Mr. Girish Alawe, General Manager – tec. nicum, highlight how Schmersal’s tec.nicum division is helping manufacturers build safer, smarter, and globally compliant production environments through advanced safety consulting, training, engineering, and digitalisation solutions. By bridging the gap between machine safety and Industry 4.0, tec.nicum is empowering Indian manufacturers to enhance productivity, reduce operational risks, and meet international safety standards with confidence.
With industries increasingly adopting connected technologies, collaborative robots, advanced machine tools, and digital production systems, the importance of machine safety has expanded far beyond basic compliance. Manufacturers today require integrated safety solutions that not only protect operators and assets but also support efficiency, flexibility, and long-term competitiveness. This is where tec.nicum plays a transformative role by offering complete machine safety expertise under one umbrella.
What is the core objective of the tec.nicum division, and how does it enhance value for machine builders and manufacturers?
The core objective of Schmersal’s tec.nicum division is to provide manufacturer-neutral safety consulting, training, digitalisation of safety systems, and engineering services that ensure machines and workplaces comply with international safety standards.
For machine builders and manufacturers, this brings immense value by reducing compliance risks, simplifying certification procedures, and enabling safer and more efficient operations. With a worldwide network of safety experts, tec.nicum provides borderless support, allowing manufacturers to access expert guidance without limitations of geography, language, or time zones. This global support structure helps industries accelerate machine commissioning while maintaining world-class safety standards.
In today’s globally connected manufacturing environment, companies supplying products to international markets must comply with stringent safety regulations and documentation standards. tec.nicum supports organizations in understanding these requirements at every stage of machine design and operation. By helping manufacturers identify potential hazards early and implement structured safety strategies, the division minimizes costly redesigns, production interruptions, and compliance-related delays.
The division’s manufacturer-neutral approach further strengthens customer confidence because recommendations are based entirely on application requirements and global safety best practices. This ensures industries receive customized and practical safety solutions aligned with their operational goals.
How does tec.nicum support industries in implementing advanced machine safety solutions beyond standard product offerings?
tec.nicum goes beyond supplying safety products by offering complete end-to-end machine safety solutions. The process begins with educating customers about machine safety, followed by detailed risk assessments and implementation of suitable technical solutions.
The division helps industries design, retrofit, and operate machines with customized safety systems that align with specific production requirements. This holistic approach not only ensures compliance with global regulations but also improves operational efficiency, minimizes downtime, and supports future-ready smart manufacturing integration.
By acting as a strategic partner rather than just a product supplier, tec.nicum ensures safety solutions become an integral part of production and business growth strategies.
A major advantage of tec.nicum’s approach lies in its ability to support industries throughout the complete machine lifecycle. Whether it involves designing new production lines, upgrading existing equipment, or integrating advanced automation technologies, tec.nicum provides technical expertise that helps industries achieve safer and more reliable operations.
The division also focuses on practical implementation rather than theoretical compliance alone. Its engineering teams work closely with manufacturers to ensure safety systems integrate seamlessly into machine operations without compromising productivity. This balanced approach allows industries to improve machine availability, reduce unexpected downtime, and maintain operational continuity while meeting international safety expectations.
What role does tec.nicum play in training and upskilling engineers on functional safety and global standards?
The tec.nicum Academy serves as a global knowledge hub focused on developing expertise in functional safety and international compliance standards. It offers internationally recognized certification programs and practical training courses on standards such as ISO 13849, IEC 62061, and CE directives.
These programs equip engineers with the skills needed to design, validate, and implement machine safety systems effectively. Each certification concludes with a rigorous examination conducted by TÜV Rheinland, and successful candidates receive official TÜV certification.
This training ecosystem significantly benefits industries by creating a highly skilled workforce capable of handling increasingly complex automation and safety requirements.
As industrial automation systems become more sophisticated, the demand for qualified safety professionals is rising rapidly. Many industries today face a shortage of engineers with practical knowledge of machine safety principles and international compliance frameworks. tec.nicum addresses this gap by combining theoretical learning with real-world application-based training modules.
The programs offered by tec.nicum Academy not only improve technical competency but also create greater awareness about safety culture within organizations. Engineers trained through these programs are better equipped to identify risks, implement preventive measures, and ensure safe operation of modern automated systems.
This capability becomes especially important for manufacturers operating in highly regulated sectors such as automotive, aerospace, electronics, pharmaceuticals, and heavy engineering, where safety compliance directly impacts business credibility and export opportunities.
How are Industry 4.0 and smart automation influencing safety system design at Schmersal?
Industry 4.0 and smart automation technologies are transforming safety system design by enabling intelligent, connected, and self-monitoring safety components. Schmersal integrates technologies such as IO-Link Safety into digital communication networks, allowing real-time diagnostics, interoperability, and greater flexibility for smart factories.
Additionally, tec.nicum has developed digital solutions like tec.ps, a Product Service System software platform that extends machine safety beyond hardware. It helps manufacturers manage safety processes, compliance documentation, and lifecycle management digitally. These innovations allow manufacturers to achieve higher productivity, predictive maintenance capabilities, and enhanced operational transparency without compromising safety.
The evolution of connected manufacturing has created a strong need for safety systems that can communicate seamlessly with automation networks and intelligent factory platforms. Modern manufacturers are increasingly seeking solutions that offer data-driven insights, remote monitoring capabilities, and predictive diagnostics.
By integrating smart safety technologies into digital manufacturing ecosystems, Schmersal and tec.nicum are helping industries move toward more efficient and transparent operations. The ability to monitor safety devices in real time improves maintenance planning, reduces machine failures, and enables faster response to operational abnormalities.
This integration of safety with digitalisation is becoming a key requirement for future-ready factories, particularly as manufacturers adopt AI-driven systems, autonomous production technologies, and collaborative robotics.
What are the major safety challenges faced by Indian manufacturers today?
Indian manufacturers face several key challenges, including limited awareness of global safety standards, compliance gaps with CE and ISO directives, increasing automation-related risks involving robots and cobots, and the challenge of integrating Industry 4.0 technologies safely.
tec.nicum addresses these challenges by helping industries improve compliance, upskill employees, and safely implement advanced automation technologies. Its strategic consulting approach enables Indian manufacturers to build globally competitive manufacturing operations while ensuring workforce protection and long-term sustainability.
Another major challenge for Indian industries is balancing productivity expectations with safety investments. Many manufacturers still perceive machine safety as a compliance requirement rather than a long-term business enabler. However, unsafe operations often result in machine downtime, workforce injuries, productivity losses, and higher operational costs.
tec.nicum helps organizations understand that effective safety implementation directly contributes to efficiency, reliability, and business continuity. By promoting a proactive safety culture, the division enables industries to reduce operational risks while strengthening global competitiveness.
As India continues to position itself as a global manufacturing hub, machine safety and international compliance will become increasingly important for export-driven industries. Companies that invest in advanced safety systems today will be better prepared to meet future regulatory and technological demands.
Can you share a real-world example where tec.nicum improved safety performance and productivity?
One notable example involved a leading Indian automotive glass manufacturer that needed both machine safety upgrades and workforce skill development. tec.nicum initially trained nearly 300 employees across multiple plant locations, out of which 50 professionals were shortlisted for advanced TÜV-certified safety programs.
In the next phase, machine safety assessments were conducted across facilities, followed by implementation of safety upgrades integrated into existing machine controls without affecting productivity. The entire project took nearly 12 to 15 months and resulted in significant improvements in machine safety compliance and workforce capability.
The project demonstrated how structured safety implementation can simultaneously improve operational efficiency, employee confidence, and long-term manufacturing reliability.
Beyond compliance improvements, the project also highlighted the importance of workforce engagement in building a successful safety ecosystem. Employees became more aware of operational risks, machine handling procedures, and preventive safety practices, creating a stronger culture of responsibility across production facilities.
The successful implementation further reinforced how safety and productivity can coexist when supported by proper planning, engineering expertise, and employee training. Instead of creating operational limitations, the upgraded safety systems contributed to smoother workflows, reduced interruptions, and better process reliability.
As industries continue moving toward highly automated and digitally connected manufacturing systems, the role of advanced machine safety solutions will become even more critical. Through its consulting expertise, training initiatives, engineering capabilities, and digital safety solutions, tec.nicum is helping manufacturers confidently navigate this transformation while ensuring safer, smarter, and globally compliant operations for the future.