E-stop: when to check for proper operation

Safety in industrial plants is an absolute must. How to take care of it? One of the most important protective mechanisms, which often decides about the health and life of employees, is the emergency stop button. It is commonly called E-stop. But its installation is only the beginning. Regular checking to see if it works properly is equally important. How often and how should it be done?

What exactly is E-stop and what is it used for?

E-stop is a button that stops a machine or an entire technological process with one movement. Although it may be inconspicuous, its role is very important. Emergency buttons are designed for crisis situations and must act immediately. Regardless of the circumstances.

This is especially important when the machine starts to pose a threat. Malfunctioning is a risk to people, equipment and the environment. This is when E-stop gives a chance to quickly control the situation.

What makes these buttons stand out? Compared to regular switches, emergency buttons are built much more solidly. They must have a locking mechanism. Once pressed, they remain in a locked position until manually released, which only happens when the threat is eliminated. This is a requirement not only of common sense, but also of numerous regulations, such as the Machinery Directive from 2005 or the ISO 13850 standard (emergency stop).

Why is E-stop crucial for safety?

In emergency situations, every second counts. An efficient E-stop can save lives, prevent costly damage and reduce the risk of major downtime. If the button does not work, the consequences can be dramatic. Both for people and for the company.

But that’s not all. Properly functioning emergency buttons are also a way to reduce the scale of material losses. What’s more, neglecting regular E-stop checks can lead to legal liability for the company. All this means that taking care of their efficiency should be as natural as daily maintenance of machines.

How often should I check the operation of my E-stops?

There is no hard and fast rule when it comes to the frequency of checks. It depends on several factors:

• type of machine operation – equipment operating in continuous mode or in difficult conditions requires more frequent checking;
• risk level – the greater the risk to people or the environment, the more frequently tests should be performed;
• manufacturer recommendations – often the instruction manual indicates exactly when to perform inspections;
• results of its own risk assessment – ​​each company should prepare a threat analysis that will indicate the optimal test schedule.

It is also good practice to quickly test E-stops after any failure, repair or before the start of a work shift.

What should an E-stop check look like, step by step?

Before starting any tests, it is a good idea to consult the machine’s operating instructions or company safety procedures. However, most of these types of activities are quite similar. A standard inspection involves several stages:

1. Visual inspection

First, take a look at the button: is it clean, undamaged, and does it work without any jams? Any mechanical damage, dirt, or improper assembly should immediately raise an alarm.

2. Test the locking mechanism

Pressing the E-stop should immediately lock the button in the emergency position. Unlocking must only be possible manually – in accordance with the manufacturer’s recommendations.

3. Functional test

The most important moment. Pressing E-stop should cause all drives to stop and safe disconnection of energy sources. In modern devices, stopping often occurs according to a specially programmed procedure. Sometimes the button also activates an alarm signal – and this also needs to be verified.

4. Documenting Results

Each test must be properly documented. The button status, any irregularities, and the inspection date must be noted. To easily control the verification results, it is best to use digital solutions. The CMMS system is perfect for this role .

Employee training – the key to success

The equipment itself is not everything. For E-stops to fulfill their function, employees must know how to use them. Therefore, regular training is just as important as inspections. Every person in the plant should know:

• where are the E-stop buttons located,
• when to use them,
• how to behave after an emergency stop.

This knowledge is essential not only for operators, but also for maintenance and technicians responsible for inspections. A conscious employee is a safer employee – and a well-trained team can significantly reduce the number of accidents in the plant.

Why is it worth investing time in E-stop checks?

E-stops are often treated as “obviously obvious” – until something happens. In the meantime, they can save lives or limit losses at a critical moment. Regular monitoring and training of staff is therefore a simple way to really increase the level of safety in the company.

Let’s remember that safety is a process, not a one-time action. Therefore, investing in the efficiency of E-stops and employee awareness always pays off – financially, image-wise and, most importantly, in terms of the safety and health of employees.