Hazard and operability study of Actiw LoadMatic loading system: development of risk management to achieve remote control and increased level of automation

Abstract

The development of remote-controlled and automated loading solutions is closely connected to the broader industrial trend toward safer and more efficient operations. However, the realisation of a fully automated loading system is not possible without comprehensive risk management and adherence to safety requirements, highlighting the importance of systematic analysis methods such as Hazard and Operability study (HAZOP).

The applicability of the HAZOP method to automated loading systems like Actiw Oy’s LoadMatic has not been extensively studied. The purpose of this thesis is to clarify how the HAZOP method can be applied to automated loading systems and to identify potential risks and deviations, particularly in the context of transitioning toward remote-controlled operations.

As part of the thesis, a complete HAZOP analysis was carried out for the LoadMatic device. The work involved analysing the system’s technical documentation, reviewing supplier materials, and assessing the readiness of key components in relation to safety, reliability, and potential optimisation. The results of the analysis are to be further examined from the perspective of implementing a remote control system, in order to assess how well the system and its key components align with the future needs of automation and remote operation.

Full autonomy in industrial loading systems remains challenging due to variable, inconsistent, and heterogeneous cargo spaces and trailers, as well as irregular and diverse unit loads. The HAZOP analysis revealed that the highest risks in normal operation stem from human factors, followed by variability in loading spaces and load unit quality. The method proved effective in systematically identifying and documenting risks, supporting both safety compliance and CE marking requirements. A modular HAZOP template was developed to meet the company’s needs, and its adoption can enhance safety, reliability, and the transition toward automated operation.