Our work

Downer - Queensland Train Manufacturing Program (QTMP)

Systems Safety Assurance for the Downer QTMP

The challenge

QTMP was established by Transport Main Roads, to support Southeast Queensland’s population growth, the opening of Cross River Rail and the Brisbane 2032 Olympic and Paralympic Games. The multi-billion-dollar project includes:

  • Design and manufacture of 65 new six-car passenger trains
  • Construction of new purpose-built manufacturing and maintenance facilities.

What we did

Plan Safe have delivered Systems Safety Assurance services for the bid and SDR phases, including development of the System Safety Management Plan for the project.

Our team is providing safety leadership, technical support, and safety strategy for the program, ensuring alignment of safety programs across all three major assets.

The outcome

Downer and its project partners are now delivering the QTMP with the support of our Rollingstock and Infrastructure safety experts.

The Plan Safe team have developed the project system safety plan, and facilitated all SDR phase workshops with Queensland Rail and Transport for Main Roads stakeholders.

Airservices Australia - Western Sydney Airport Airspace Redesign

Operational Safety and Human Factors for the new Western Sydney Airport Airspace Redesign

The challenge

To enable the new Western Sydney Airport, a new Airspace Design is being developed for the Sydney Basin. Airservices is building the safety and Human Factors case for the new design to enable safe and efficient move of air traffic once the new airport is operational.

What we did

Plan Safe are managing the entire safety
program for the new airspace design, including development of quantitative analysis techniques to ensure the safety of the new airspace. Our consultants have also provided workload assessment and task analysis based on extensive simulator exercises using the new Airspace design.

The outcome

Planning for the safe airspace change i
ongoing, including all stakeholders; CASA, Department of Infrastructure, and WSA Co. Findings delivered so far have been incorporated into an updated Airspace Design, improving safety and efficiency for the future.

Airservices Australia - Western Sydney Airport Digital Aerodrome System (DAS)

Systems Safety for the Australian First implementation of a Digital Aerodrome System (remote Air Traffic Control tower) at the new Western Sydney Airport

The challenge

To enable the ATC Tower Service at the new Western Sydney Airport, Airservices is implementing a Digital Aerodrome Services (DAS). In a DAS environment, the natural out-of-the-window view of the air traffic controllers is replaced by a visual reproduction system.

The DAS Program encompasses developing and delivering first-of-type technology as well as
establishing an operating model for ongoing support and innovation enhancements, introducing new
ways of working for Airservices.

What we did

Plan Safe are managing the entire safety
program for the new DAS solution, including development of the system safety plan, Functional Hazard Analysis and Fault Trees, Safety Case(s) and facilitating approval by CASA.

The outcome

Safety work for the DAS design is ongoing, with the program on track to support WSA in their goal of first flights in late 2026.

The DAS system will represent a fundamental transformation for air traffic in Australia, and Plan Safe are supporting the safe implementation of the system at WSA.

Windhoff - Systems Engineering and Systems Safety Assurance

Development of Systems Engineering and Systems Safety Assurance, and Project Plans for the Windhoff / Sydney Metro Train Lift project

The challenge

Sydney Metro Trains Facility(SMTF), Rouse Hill manages the operations maintenance and stabling for all Sydney Metro. The facility construction was completed in two stages, Stage 1 supporting 22 Metro trains for Sydney Metro Northwest. And, Stage 2, supporting 23 additional trains for Sydney Metro City & Southwest.

What we did

Plan Safe delivered Systems Engineering and Systems Safety Assurance services for the new train lift being delivered in the Stage 2 SMTF Expansion project. This also included Human Factors and a suite of Management Plans to meet the project milestones of design, construct, test and commissioning.

Our team developed key project plans and reports, including:

  • Project Management Plan
  • Design Management Plan
  • Safety Management Plan
  • Systems Assurance Plan
  • Human Factors Plan
  • Safety Case and Hazard Log

The outcome

The Plan Safe team successfully assisted Windhoff achieve delivery of their train lift and bogie turntable into the SMTF.

The finalised plans and reports allowed the client to get on with the design and delivery of their fantastic systems and equipment and avoid the endless loop of comments and document rejection.

Our team also successfully negotiated a tailored scope and responsibilities for our client, ensuring they were not liable for any additional work.


Thales Australia - Enterprise Network Modernisation Program

Development of Fault Tree Analysis and System Safety Assessments

The challenge

Thales is part of consortium delivering the design phase for Airservices Australia’s enterprise-wide telecommunications network. The project involves the design of the telecommunications, radio communications, ADS-B surveillance and network services systems.

What we did

Plan Safe have delivered Fault Tree Analysis for the Fast Track Program, including detailed Systems Safety Assessments and reports to demonstrate the safety of the new system.

The outcome

The reports and analysis are contributing to the delivery of a network solution that is resilient, reliable, secure and flexible to support the continued delivery of safe and secure air traffic management and aviation firefighting services across Australia.

Inland Rail - Zonal Safeworking [ZSW] Safety Assessment and Benefits Report

Safety Assessment and Assurance for the new Inland Rail Zonal Safeworking Procedure

The challenge

While building the Inland Rail, an opportunity was identified to reduce the need for Protection Officers where there is no track and no possibility of the movement of rail traffic.

What we did

Plan Safe and our partners Assured Rail Projects provided a comprehensive review and associated report, satisfying all ONRSR requirements and demonstrating that the application of ZSW ensures safety, SFAIRP

The outcome

The report confirmed the safety of the updated Zonal Safeworking procedures and provided data that detailed how ARTC will benefit from avoiding direct and indirect costs on Inland Rail, and potentially across the wider ARTC business, from not needing to deploy a Protection Officer per Worksite.

Airservices Australia - Integrated Drone Surveillance System (IDSS) Trial

Systems Safety Assurance for the Integrated Drone Surveillance System (IDSS) trial at Sydney Kingsford Smith Airport

The challenge

With the use of drones for commercial and leisure purposes expected to grow exponentially, it is becoming a necessity to identify and efficiently manage their activity near airports.

What we did

Plan Safe and our partners ALARP Solutions have been delivering Systems Safety Assurance activities for the trial, including development of the Functional Hazard Analysis.

The outcome

The trial of next-generation drone detection capabilities allows Airservices to continue to enhance the safe operation of crewed and uncrewed flights operating together in Australian airspace.

Airservices Australia - Brisbane 7 Knot Tailwind Safety Case

Safety Case for the 2 knot increase of tailwind take off and landings at YBBN

The challenge

As part of the Brisbane New Runway Project Implementation Review, BAC and Airservices are exploring options that would allow more planes to depart and land over Moreton Bay.

What we did

Plan Safe and our partners ALARP Solutions developed a safety case and supporting material to request an increase in the tailwind limit for Simultaneous Opposite Direction Parallel Runway Operations (SODPROPS) at Brisbane Airport, from 5-knots to 7-knots.

The outcome

If approved by the Civil Aviation Safety Authority (CASA), the overall volume of time that arrivals and departures will be able to operate simultaneously over the bay will be increased.

Siemens - Edmonton to Gordonvale Level Crossing Removals

Systems Safety Assurance for the project design, construction and commissioning phases

The challenge

As part of the 10km Bruce Highway duplication near Cairns, the project included:

  • Realignment and upgrade of 4.5km of the Queensland Rail North Coast Line to accommodate the duplicated highway.
  • Removal of multiple at grade rail crossings and upgrade of boom gates at other crossings.

What we did

Plan Safe have delivered Systems Safety Assurance services, including development of all hazard assessments and safety cases for the project.

The outcome

The removal of the two level crossings will mean safer rail and road journeys for residents and visitors to North Queensland.

Downer - Waratah and SGT ATP (European Train Control System) Project

Providing Systems Safety leadership for the SIL4 rated ATP (European Train Control System) upgrade of the Waratah Train Fleet (A-Sets) and SGT (B-Sets)

The challenge

As part of the Automatic Train Protection (ATP) Project, the $120M Waratah ATP upgrade is required to provide additional safety benefits and more reliable services by ensuring trains operate within the permitted speed limit.

What we did

We were the system safety consultant for the project, providing specialist expertise to ensure the safe implementation of this critical safety system. Our consultants provided design safety assurance for the new ETCS system including management of all software safety aspects.

The outcome

Plan Safe has delivered systems safety for the world’s first fully redundant integrated ATP/TCMS Driver workstation. The delivered ETCS workstation includes redundant displays with a first-of-its-kind manually selected Day/Night mode colour palette applied to the entire Driver Machine Interface.

Airservices Australia - Melbourne Aerodrome Lighting Upgrade

Systems safety assurance for airfield lighting upgrades 2021

The challenge

As part of the APAMs required aerodrome lighting upgrades to ensure compliance with CASR139, Airservices are required to integrate the modern highly controllable lighting updates into INTAS (Integrated Tower Automation Suite).

What we did

Plan Safe are delivering the safety assurance program for the project. Our consultants are providing safety assurance services for the new lighting control upgrades.

The outcome

Once the projects initiated by APAM have been completed, there will be additional functionality and support for ATC when managing traffic within the manoeuvring area, which increases flexibility. This functionality includes the introduction of additional Stop Bars and the MOWP functionality for lighting maintenance.

Downer - Sydney Growth Trains (SGT)

Systems safety assurance for new trains 2017 to 2021

The challenge

As part of the $1.5 billion More Trains, More Services program, the Sydney Growth Trains project aims to provide customers with a new fleet of 24 eight-car comfortable, air-conditioned trains.

What we did

We were heavily involved in the designing and implementing the system safety assurance program for the project. Our consultants provided design safety assurance for the new rolling stock and management of dynamic testing safety activities.

The outcome

The Sydney Growth Trains project has delivered 24 modern, double decked trains to the people of Sydney, with a further 17 trains in production. It is the fastest ever delivery of trains from contract signing to passenger service in Australia.

Integrated management system development

Safety management systems certification 2017 certified

The challenge

A large company working at the forefront of facilities management in high profile industries required a new management system to allow certification to international standards.

What we did

Developed a fully integrated management system and assisted the client with certification to ISO 9001, 18001 and AS4801.

The outcome

The client has doubled their size due to new contract wins, helped by their certified and integrated management system.

Yarra Trams - Safety management system improvement

Safety management systems update 2017

The challenge

In preparation for a refranchising exercise, this major Australian tram operator required updates to its Safety Management System.

What we did

Developed Engineering Safety Assurance, Human Factors and Fatigue Management Programs and Procedures.

The outcome

The client has improved their maturity and systems in relation to Engineering Safety Assurance, Human Factors and Fatigue Management.

Instrument landing system (ILS) cat IIIb upgrade

Perth airport systems safety assurance 2015 to 2016

The challenge

While fog is a relatively uncommon occurrence at Perth Airport, each year, around a dozen such weather situations arise and cause significant and costly disruptions to operations and air services.

What we did

Plan Safe consultants provided systems and software safety assurance to the ILS and lighting system changes. Perth Airport manages up to 400 flight movements per day and needed to remain operational throughout construction.

The outcome

With the Category I to a Category IIIB lighting and aerodrome upgrade now in place, Perth Airport is now more attractive for long-haul flights, and even secured the highly-anticipated Qantas direct flight to London.

Mt Barrow communications tower replacement

Systems safety assurance for infrastructure 2015 to 2016

The challenge

Aging air navigation and communications infrastructure required replacing at the highest mountain in Tasmania.

What we did

We provided system safety assurance services for the design and construction of the replacement tower and associated infrastructure.

The outcome

A new tower was able to be constructed using helicopters, while maintaining full coverage of navigation and communications services throughout the build.
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