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Operators load parts into robot cells every shift. Robots pick, weld or sort those parts, and the cycle starts again, thousands of times a day. When people work this close to machines, safety matters.
ISO/TR 20218-2:2017 gives plant managers, production teams and safety staff clear guidance on manual load/unload stations. Global Certification Services (GCS) helps manufacturers apply it with ISO 10218-2:2025, ISO 45001 and ISO 9001, so operations stay safe and audit-ready.
GCS supports manufacturers across the Middle East, GCC, Africa, Europe, Central Asia and Asia. See the countries we serve.
What Is a Manual Load/Unload Station?
A manual load/unload station is a spot in a robot cell where a person puts parts in or takes parts out by hand while the robot works nearby. Common examples:
- A worker loads raw parts, and the robot picks them up
- Staff stack or unstack items next to a robot arm
- A person fits a part before the robot finishes the job
- Operators feed materials into a robotic packing line
Full automation is not always possible. Some parts are too fragile or too varied for a robot alone, so a person steps in. That also puts a person next to a fast-moving machine, which is exactly where ISO/TR 20218-2 helps.
What Is ISO/TR 20218-2?
ISO/TR 20218-2:2017 is a Technical Report from ISO. Its full title is “Robotics — Safety design for industrial robot systems — Part 2: Manual load/unload stations.”
It covers robot systems where guards block access to the hazard zone while a person loads or unloads parts. It looks at two things together: how to restrict access and how to design an ergonomic workstation. It gives guidance, not fixed numbers or exact specs. Read our ISO/TC 299 robotics standards guide ISO/TC 299 Robotics Standards page.
Key things to know:
- It is not a certification standard
- It does not replace ISO 10218-2
- It gives guidance, not rules
- It shows how to apply robot cell safety rules to a real loading station
Is ISO/TR 20218-2 Still Valid?
Yes. ISO still lists ISO/TR 20218-2:2017 as published, and no replacement is in development. Check the live status on the official ISO/TR 20218-2:2017 page.
The standard it supports has changed, though. ISO wrote this report to support ISO 10218-2:2011, which ISO has since replaced with ISO 10218-2:2025 ISO 10218-2:2025 page. The 2025 edition now covers manual load/unload stations in its main text. Read ISO/TR 20218-2 alongside ISO 10218-2:2025, not the old 2011 edition.
Technical Report vs Technical Specification vs International Standard
ISO publishes different types of documents. Here is what each one means:
| Document Type | What It Does | Sets Requirements? | Example |
| International Standard | Sets requirements that products or systems must meet | Yes | ISO 10218-2:2025 |
| Technical Specification | Gives detailed guidance in a fast-moving area | Guidance, not full consensus | ISO/TS 15066:2016 |
| Technical Report | Shares guidance and examples | No | ISO/TR 20218-2:2017 |
ISO/TR 20218-2 helps you make good design choices. For formal requirements, use ISO 10218-2:2025. For a certified safety management system, use ISO 45001.
What Are the Main Hazards at Robot Loading Stations?
At every loading station, one risk stays constant: a person and a robot share the same space. Knowing where dangers come from helps you design a safer station. Common hazards include:
- Unexpected robot movement: poor timing between person and robot
- Reaching into the work area: on purpose or by accident
- Poor visibility: blind spots in the cell
- Heavy, sharp or awkward parts: strain or injury during handling
- Production pressure: fast lines leave less time to be careful
Check each station for its own hazards. Never assume another cell’s risk assessment covers yours.
ISO Standards
- ISO 9001 Certification
- ISO 14001 Certification
- ISO 45001 Certification
- ISO 22000 Certification
- ISO 27001 Certification
- ISO 13485 Certification
- ISO 50001 Certification
- ISO 37001 Certification
- ISO 21001 Certification
- ISO 41001 Certification
- ISO 22301 Certification
- ISO 27701 Certification
- ISO 42001 Certification
- ISO 21678 Certification
- ISO 22241 Certification
- ISO 22716 Certification
- ISO 26000 Certification
- ISO 27031 Certification
- ISO 46001 Certification
- ISO 80079-34 Certification
- SA 8000 Certification
- ISO 30401 Certification
- ISO 20121 Certification
Why Do Operators Bypass Guards at Loading Stations?
Operators usually bypass guards for one reason: the guard makes the job slower or harder. It is rarely about carelessness. It is about pressure. When the safe way takes longer, people find a faster way.
Awkward Reach and Poor Height
When a station does not fit the operator’s body, they stretch, twist or lean around a guard to reach a part.
Slow Reset and Restart
When resetting a guard takes too long, operators skip it, especially on fast lines.
Pressure on Cycle Time
When speed is the target, every second counts. Guards that slow the task become a problem.
Unclear Instructions and Training
Operators who do not understand why a guard exists are more likely to ignore it.
A warning sign alone will not fix this. The station has to work well for the operator. When the safe way is also the easy way, people use it. That is why ISO/TR 20218-2 treats ergonomic design as part of safeguarding.
Seeing workarounds at your robot cells?
What Are the Key Safety Design Principles for Loading Stations?
These are design principles, not exact measurements.
Keep People Out of the Hazard Zone
Guards and barriers stop operators from entering the robot’s work area during operation.
Stop Reaching Over, Under, Around or Through
The layout should make safe loading physically easy, with no need to reach past a guard.
Safe Reset and Restart
Give operators a clear, simple way to reset and restart the station. If this step feels slow or confusing, people skip it.
Ergonomic Station Design
Make the station comfortable to use, with parts easy to pick up and place. Good design reduces strain and the urge to take shortcuts.
Safe Access for Maintenance
Maintenance staff need safe access too. Design for maintenance, not just normal operation.
Clear Instructions and Training
Every operator should know what to do, what to avoid and why. Good training is part of safe station design.
These principles apply across many industries, including automotive manufacturing, where robot cells and manual stations often sit side by side.
Can You Balance Cycle Time and Safety?
Yes. Plant managers often feel they must choose between speed and safety. A well-designed station removes most of that conflict and runs more smoothly, with:
- Fewer unplanned stops
- Fewer near-misses
- Fewer workarounds that cause problems later
When the safe way is also the fast way, you meet both goals.
How Does ISO/TR 20218-2 Fit With ISO 10218-2:2025?
ISO 10218-2:2025 is the current standard for industrial robot application and robot cell safety. It now includes requirements for manual load/unload stations.
ISO/TR 20218-2:2017 came out before the 2025 edition. Use ISO 10218-2:2025 for current requirements. Use ISO/TR 20218-2 to see how those requirements work at a real loading station.
ISO/TR 20218-2 vs ISO/TR 20218-1 – What Is the Difference?
These two reports cover different topics:
- ISO/TR 20218-2:2017 covers manual load/unload stations, where a person feeds or empties a robot cell by hand
- ISO/TR 20218-1:2018 covers robot end-effectors, such as grippers and tools on the robot arm
They are not interchangeable. When the robot’s tooling affects your station design, both reports help. Read our ISO/TR 20218-1 guide ISO/TR 20218-1 page.
Is a Loading Station a Collaborative Application?
No. These two setups often get confused, but they work differently.
At a manual loading station, the person and the robot take turns. Guards and timing keep them apart. In a collaborative application, the person and the robot work in the same space at the same time, under different rules.
ISO/TR 20218-2 covers loading stations, not collaborative setups. For true human-robot collaboration, use ISO 10218-2:2025 as your main reference, with ISO/TS 15066 as background. Read our ISO/TS 15066 guide ISO/TS 15066 page.
Can You Get ISO/TR 20218-2 Certification?
No. ISO/TR 20218-2 is a guidance document, and ISO itself never issues certificates. Nobody can audit or certify a business against this report.
You can use it as a guide while you work toward certifiable standards:
- ISO 45001 certification for occupational health and safety management
- ISO 9001 certification for quality management
These certifications show clients, auditors and regulators that your systems meet recognised standards. GCS supports you with both.
How to Review a Loading Station
Use this simple approach to review your loading station safety.
1. Check Current Standards and Editions
Confirm you work with ISO 10218-2:2025, not the old 2011 edition.
2. Watch the Operator’s Real Task
Watch how the operator actually works every day, not how the designers expected the station to run.
3. Find Every Way Into the Hazard Zone
Look for any gap, opening or route an operator could use to reach the robot’s work area.
4. Review Guards, Reset and Restart
Check that guards are in good condition. Make sure the reset and restart steps are clear and practical.
5. Review Reach, Height and Lifting
Check that operators can reach parts easily without stretching or twisting.
6. Check the Station Within the Full Cell
The station never works alone. Check how it fits the full robot cell and the ISO 10218-2:2025 requirements.
7. Record Actions and Train Staff
Write down what you find and what you plan to fix. Train every operator on the changes.
How Does Loading Station Safety Link to ISO 45001?
ISO 45001 is the international standard for occupational health and safety management. It helps companies find risks, set controls and keep improving across the whole workplace, including robot cells.
When you use ISO/TR 20218-2 guidance inside an ISO 45001 system, you do not fix loading station risks just once. You track, review and improve them over time. GCS supports manufacturers working toward ISO 45001 certification, including robot cell risk records and loading station controls.
ISO/TR 20218-2 and Global Regulations
ISO/TR 20218-2 is guidance, not a law. Rules vary across regions, and buyers or contracts may name specific standards.
- European Union: The EU Machinery Regulation (EU) 2023/1230 applies from January 2027. Plants and integrators serving Europe should align with ISO 10218-2:2025 before then.
- GCC, Middle East, Africa, Central Asia and Asia: Local authorities may set their own documentation or inspection rules. Check them before you design or change a station.
GCS helps manufacturers align ISO/TR 20218-2 guidance with ISO 10218-2:2025 and local rules. See the countries we serve for region-specific support.
Loading Station Safety Checklist
Use this as a starting point for your own review:
- You mapped and documented the station layout
- You identified the hazards for this specific station
- You checked guards for real-world usability, not just design
- You asked operators about workarounds and problems
- You checked the station against ISO 10218-2:2025
- Your risk assessment records are complete and current
- You linked findings to your ISO 45001 system
- You set a follow-up review date
How GCS Supports Robot Cell Safety
Global Certification Services (GCS) helps manufacturing, production and EHS teams apply ISO/TR 20218-2 to real stations, not just paperwork. Our support includes:
- Standards guidance: how ISO/TR 20218-2 and ISO 10218-2:2025 apply to your cell
- Loading station gap review: where your current setup falls short
- Risk assessment records: clear and audit-ready
- ISO 45001 certification: station safety built into a formal management system
- ISO 9001 support: safety design aligned with production quality
We give practical guidance, not just templates, and we help at every step from gap review to certification across the Middle East, GCC, Africa, Europe, Central Asia and Asia.
Make Your Loading Stations Safer With GCS
Your loading stations run every day. They deserve the same care as every other part of your safety system. GCS helps you apply ISO/TR 20218-2, align with ISO 10218-2:2025 and build the records your ISO 45001 and ISO 9001 systems need.
ISO/TR 20218-2 FAQs
What is ISO/TR 20218-2?
ISO/TR 20218-2:2017 is an ISO Technical Report on the safe design of manual load/unload stations in robot cells. It covers access restrictions that keep people out of hazard zones and ergonomic workstation design. ISO/TC 299 developed it to support ISO 10218-2, and ISO published it in December 2017.
What is a manual load/unload station?
It is a place in a robot cell where a person loads or removes parts by hand while the robot works nearby. Guards, light curtains and timing controls keep the person out of the robot’s hazard zone. Common examples include welding, packing and assembly cells fed by operators.
Is ISO/TR 20218-2 still valid?
Yes. ISO still lists ISO/TR 20218-2:2017 as published, with no replacement in development. ISO wrote it to support ISO 10218-2:2011, which ISO has since replaced with ISO 10218-2:2025. The 2025 edition now covers load/unload stations in its main text, so read both documents together.
Why do operators bypass robot guards?
Operators usually bypass guards when the guard makes the job slower or harder. Awkward reach, slow reset and restart, cycle time pressure and unclear training are the main causes. A good station makes the safe way the easy way, so people have no reason to take shortcuts.
What is the difference between ISO/TR 20218-1 and ISO/TR 20218-2?
ISO/TR 20218-2 covers manual load/unload stations, where a person hands parts to or takes parts from a robot cell. ISO/TR 20218-1 covers end-effectors, meaning the grippers and tools on the robot arm. They cover different topics, and many cells benefit from both reports.
Is ISO/TR 20218-2 a certification?
No. ISO/TR 20218-2 is a guidance document, and ISO itself never issues certificates. Nobody can certify a business to a Technical Report. Plants can still pursue ISO 45001 for workplace safety and ISO 9001 for quality, using the report to guide their station design and risk controls.
How can GCS help with loading station safety?
GCS explains ISO/TR 20218-2 and ISO 10218-2:2025 in plain language and reviews your loading stations on the shop floor. Our team helps you build audit-ready risk assessment records. We also support ISO 45001 and ISO 9001 certification across the Middle East, GCC, Africa, Europe, Central Asia and Asia.