SafeDesign: Modern Safety Designs for Improved Safety & Productivity Host: Dan Hornbeck Rockwell Automation Safety Business Development Manager

Size: px

Start display at page:

Download "SafeDesign: Modern Safety Designs for Improved Safety & Productivity Host: Dan Hornbeck Rockwell Automation Safety Business Development Manager"

Gavin Underwood
5 years ago
Views:

1 Insert Photo Here SafeDesign: Modern Safety Designs for Improved Safety & Productivity Host: Dan Hornbeck Rockwell Automation Safety Business Development Manager Copyright 2010 Rockwell Automation, Inc. All rights reserved.

2 Today s Agenda 1. Review of our Last Webinar-Overview of Standards 2. Safety as a Core System Function 3. Functional Safety Life Cycle 4. Emerging Design Philosophies 5. Application Examples 6. The Rockwell Automation Safety Community and Future Educational Opportunities 7. Questions

3 Today s Speakers Derek Jones Rockwell Automation Safety Business Development Manager George Schuster - CFSE Rockwell Automation Detroit Senior Industry Consultant

4 Highlights from the Last Session The EU Machinery Directive and Overview of Standards The global machinery market and the influence of the European System Overview of EU directives that may need consideration New Machinery Directive in particular Role of standards in general and their globalization Functional safety standards and implications for global machinery market Derek Jones Rockwell Automation Safety Business Development Manager

Copyright 2010 Rockwell Automation, Inc. All rights reserved. Standards - EN, ISO and IEC EXAMPLES: Type A EN ISO 12100 Safety of machinery.

5 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Standards - EN, ISO and IEC EXAMPLES: Type A EN ISO Safety of machinery. Basic terminology and methodology EN ISO Safety of machinery. Risk assessment Type B EN ISO Safety related parts of control systems EN ISO Emergency stop function EN / IEC Functional safety of electrical control systems EN / IEC Safety of machinery. Electrical Equipment EN 574 / ISO Two hand controls Type C EN ISO Earth Moving Machinery EN ISO Safety requirements for dry-cleaning machines

Functional safety standards Generic Electrical Control Systems Process Electrical Control Systems IEC/EN 61508 IEC/EN 61511 SIL Machinery

6 Functional safety standards Generic Electrical Control Systems Process Electrical Control Systems IEC/EN IEC/EN SIL Machinery Electrical Control Systems Machinery Control Systems (All technologies) IEC/EN EN ISO : 2006 PL Commonality across sectors and geographies

EN ISO 13849-1 Safety related parts of control systems - Machinery 1.

7 EN ISO Safety related parts of control systems - Machinery 1. Determine the Required Performance Level 2. Decide on the Category SISTEMA 3. Get the Data 4. Do the Calculation

8 Modern Safety Thinking: Improving Safety & Productivity George Schuster - CFSE Rockwell Automation Detroit

9 Safety as a Core System Function Safety continues to emerge as core system function Value Safety as a Key Differentiator: Global Compliance Common Designs Reduced Costs Increased Productivity Systematic MTTR Reduction Improved Competitiveness Reduced Floor Space and Direct Labor Improved Ergonomics Copyright 2010 Rockwell Automation, Inc. All rights reserved. 9

10 Safety as a Core System Function But How? New Tools: Emergence of Global Specifications ISO, IEC Standard Machine Designs that are Globally Compliant New Safety Technologies Tools for Improved Machine Performance New Design approaches Passive, Configurable and Lockable Design-In Safety for user-friendly machines A Systematic Design Approach is Required. These systems don t just happen! The Rigor of The Functional Safety Lifecycle Safety By Design Safety is a Way of Life Copyright 2010 Rockwell Automation, Inc. All rights reserved. 10

11 Functional Safety Life Cycle STEP 5 MAINTAIN & IMPROVE SAFETY SYSTEM STEP 1 RISK OR HAZARD ASSESSMENT MACHINE SAFETY LIFE CYCLE STEP 4 SAFETY SYSTEM INSTALLATION & VALIDATION STEP 3 SAFETY SYSTEM DESIGN & VERIFICATION STEP 2 STEP 2 SAFETY SYSTEM FUNCTIONAL REQUIREMENTS Copyright 2010 Rockwell Automation, Inc. All rights reserved. 11

Functional Safety Do we have a Problem? Are Safety Procedures Ever Bypassed? Do People take the Short Cut to expedite maintenance procedures? Is LOTO (Lock Out Tag Out) always followed?

12 Functional Safety Do we have a Problem? Are Safety Procedures Ever Bypassed? Do People take the Short Cut to expedite maintenance procedures? Is LOTO (Lock Out Tag Out) always followed? Are Safety Systems or Technologies ever Bypassed? Are people using a Cheater Key? Note: Some systems are so poorly designed and integrated that maintenance people are forced to bypass the safety system just to get their jobs done! Safety must be Easy and Intuitive

13 Risk Assessment The Foundation Provides Safety Performance Level Design Target Creates the Foundation of the Safety System Functional Requirements, System Design and Validation Protocol. Shows Due Diligence and Global Compliance (Ref. ISO 14121) Steps Include: Identification of Cross- Functional Team Determination of Machinery Limits & Functions Identification of Tasks & Associated Hazards Risk Estimation & Evaluation Risk Reduction and Mitigation Documentation Task/Hazard S1 S2 F1 F2 F1 F2 Performance Performance Level, PLr Level, PLr Copyright 2010 Rockwell Automation, Inc. All rights reserved. 13 P1 P2 P1 P2 P1 P2 P1 P2 S = Severity F = Frequency or Duration of Exposure P = Avoidance Probability a a b b c c d d e e Contribution Contribution to Risk to Risk Reduction Reduction Low High

Emerging Design Philosophies Passive System Design Ensures the easy way is the safe way Configurable System Design Ensures the necessary functionality to accommodate complex and variable maintenance

14 Emerging Design Philosophies Passive System Design Ensures the easy way is the safe way Configurable System Design Ensures the necessary functionality to accommodate complex and variable maintenance procedures by design. Helps to limit exposure to hazards while removing the need or incentive to bypass. Lockable Safety Systems ANSI Z244-1 Compliant Systems that systematically reduce MTTR/downtime Safety AND Productivity Copyright 2010 Rockwell Automation, Inc. All rights reserved. 14

Safety Application - Perimeter Guarding Point Point of of Entry Entry Configurable Configurable Safety Safety System System Gate Entry Box Robots OFF (AUTO) Outputs ON,

15 Safety Application - Perimeter Guarding Point Point of of Entry Entry Configurable Configurable Safety Safety System System Gate Entry Box Robots OFF (AUTO) Outputs ON, Servos OFF Outputs ON, Servos ON Tooling OFF (AUTO) Tool Outputs ON, Transfer Motion OFF Tool Outputs ON, Transfer Motion ON Easy, Easy, Intuitive Intuitive and and Secure Secure

16 Realization Example

17 Realization Example Tooling

18 Realization Example Tooling Robots

19 Realization Example Tooling Robots Transfers

20 Realization Example Robots Tooling All Configured and Locked at Point of Entry Passive, Passive,Configurable, Configurable,Lockable Lockable Transfers

Results!! Safety Application - Perimeter Guarding No need to bypass the safety system - It is designed to safely accommodate the maintenance and operating procedures.

21 Results!! Safety Application - Perimeter Guarding No need to bypass the safety system - It is designed to safely accommodate the maintenance and operating procedures. Higher productivity - Safety system may be used in lieu of LOTO ( Lockout/Tagout) for many routine maintenance and setup procedures. Improved MTTR, faster start-ups, highly standardized approach System is PASSIVE The Easy Way is the Safe Way. System is Lockable Reduction of injuries and associated costs. Engineered and Integrated Safety Systems

22 Improved Productivity by Design: MTTR Reduction Typical Downtime Event Running Running Down MTTR = 12 minutes (avg.) Machine Stops Maintenance Arrives Fault Identified LOTO Repair Performed Machine Unlocked Machine Unlocked Repair Tested Machine back in Auto Production Resumes Copyright 2010 Rockwell Automation, Inc. All rights reserved. 22

23 Improved Productivity: Safety System Design If the safety system design meets target safety level, and ANSI Z244-1 applies The safety system may be used in lieu of LOTO, reducing MTTR by ~2 minutes. Manufacturer s value of 1 minute of production = $10K Average downtime events per plant per year = 3000 (8/day) Value of safety solution due to improved productivity (reduced MTTR) $10K X 2min X 3000 = $60M/yr Safety = Productivity = Profitability

Example: Injury Reduction = Cost reduction Large global manufacturer Diverse processes and thousands of employees Implemented comprehensive safety programs based

24 Example: Injury Reduction = Cost reduction Large global manufacturer Diverse processes and thousands of employees Implemented comprehensive safety programs based on the Functional Safety Life Cycle Full commitment from Sr. Management to safety Included Risk Assessment Specifications Machinery safety Training And much more

Example: Injury Reduction = Cost reduction Single Measure OSHA Lost Work Day Case Rate Reduced from 17000 10000 annual OSHA LWDC Ave. cost = $28,000./ea (Ref. www.osha.

25 Example: Injury Reduction = Cost reduction Single Measure OSHA Lost Work Day Case Rate Reduced from annual OSHA LWDC Ave. cost = $28,000./ea (Ref. *7000 cases reduced X $28K/ea = $196,000,000. Single Measure OSHA Reportables Reduced OSHA Reportables from annual OSHA Ave. cost = $7000./ea (Ref. *4000 cases reduced X $7K/ea = $28,000,000 *Calculated Savings

Integrated into the control, information and people systems Leverage Internal and External application

26 Summary The Safety Life Cycle provides the roadmap to compliant, safe and defensible system designs. Well designed systems improve both Safety and Productivity. Safety is a System Solution not just components. Integrated into the control, information and people systems Leverage Internal and External application knowledge and expertise Maintenance, Engineering, Operations, Suppliers Safety is a shared responsibility. We are all stakeholders!

27 Thank You! George Schuster - CFSE Rockwell Automation Detroit

28 Where to begin Rockwell Automation Can Help You Get Started

2010 Functional Safety Webinar Series Rockwell Automation will be hosting an ongoing series of educational webinars to provide the most current information on Functional Safety Directives and

29 2010 Functional Safety Webinar Series Rockwell Automation will be hosting an ongoing series of educational webinars to provide the most current information on Functional Safety Directives and Practices. Our next webinar will be: March 25, 2010 SafeDesign: Machine Risk & Hazard Assessment *Invitations and announcements with all the details will be forthcoming. Exact time subject to change.

30 Join our Safety Community Rockwell Automation Safety Portal RAGuard Safety Automation Forum group Rockwell Automation Safety Solutions

31 Questions?

Ensuring Machinery Safety, Compliance, and Productivity. PackExpo - September 2015

- 5058-CO900H Ensuring Machinery Safety, Compliance, and Productivity. PackExpo - September 2015 Steve Ludwig Program Manager, Safety George Schuster Global Safety Business PUBLIC Agenda Challenging Perceptions