Smart Safety. information from the safety system. products, solutions and services. The Connected Enterprise. n Increase productivity

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1 Smart Safety n Increase productivity n Minimise downtime with diagnostic information from the safety system n Benefit from the broadest portfolio of safety products, solutions and services n Enable smarter machines for use in The Connected Enterprise

2 Smart Safety enabling smarter machines and equipment Harnessing the power of safety and operational data can substantially improve safety compliance and performance. Accessing safety system data and transforming it into meaningful information results in increased machinery productivity, and minimises downtime. To gain more diagnostic data traditional safety devices required more complex wiring solutions. With a Smart Safety solution, you can now access more diagnostic data and simplify your wiring system. An integrated Smart Safety solution provides all the data needed to create a comprehensive picture of the status of the machine or production line. Challenges to safe operations Worker behaviours Operators bypassing poorly designed safety systems Systems that don t account for procedural anomalies Standard operating procedures not being followed Evolving workforce Safety implications of major workforce shift worldwide Older workers nearing retirement at higher risk for musculoskeletal injuries Younger, less experienced workers more prone to injury Machinery downtime Downtime for jams, misfeeds, adjustments, changeovers and maintenance Minimal visibility of downtime information No context of downtime issues (workers interaction, machinery fault, shift patterns) Limited information to remedy issues Regulatory compliance Compliance with industry standards can be challenging Documenting and reporting on approved safety systems can be challenging Data management Continuing reliance on outdated data collection and reporting methods Safety data often manually entered for inspections, compliance logs, incident reports, training and other processes Systems in which data is stored typically not connected to plant floor systems Smart Safety 2

3 Access to real-time data and seamless connectivity is transforming the production environment. Smart capabilities enable end users to gain new efficiencies, improve product quality and make operations more responsive. Smart Safety helps to standardise machinery and safety control. These systems are less susceptible to nuisance shutdowns and can help to improve productivity and profitability. Why is the E-stop function being operated so much? SAFE SPEED ACTIVATION OBJECT DETECTED. Average times per hour PALLETIZER ACCESS Requests in 24hrs LOW MARGIN Per week ! Low Margin! Cleaning required Number of operations monitored for replacement scheduling. DAMAGED SWITCH!!!!! Damaged Switch! Zone 1, Conveyor! EMERGENCY STOPS Times tripped per day ! Misalignment! Line 1, guard door 3! LIGHT CURTAIN Times tripped per day Smart Safety 3

4 Smart Safety devices Smart Safety solutions provide detailed diagnostic data to your design environment, visualisation system, information software, and GuardLogix Programmable Automation Controller The Connected Enterprise/Industry 4.0 enabling Smart Machines for use in The Connected Enterprise and helping to increase productivity and minimise downtime while reducing total cost of ownership. Visualisation Design Environment Information Software Logix Programmable Automation Controller Benefits of Smart Safety EtherNet/IP EtherNet/IP Input Logic Output Safety over GuardLink (up to PLe SIL3) Safety over EtherNet/IP (up to PLe SIL3) Emergency stop Non contact switches Guard locking switches Key Interlock Switches Cable pull switches Multifunctional Access Box Light Curtains Safety Scanner Cable reduction of up to 38% Smart Safety 4

5 Smart Safety enables Smart Machines for use in The Connected Enterprise A solution incorporating Smart Safety devices enables safety professionals to transform the way they monitor and manage safety. Rockwell Automation provides a complete Smart Safety solution to meet safety requirements, covering safety input devices, safety logic and safety output devices. SOFTWARE Improve insight into worker behaviour and compliance By incorporating safety information into EHS management systems, day to day discrepancies between policies and operating procedures can be identified Enhance safety Connecting people, equipment and worksites creates new opportunities to enhance worker and environmental safety, including remote access, operations visibility, worker locating and information delivery via mobile devices. APPLICATION KNOWLEDGE HMI INDUSTRY SOLUTIONS INTEGRATED SAFETY SOLUTIONS Reduce safety-related downtime Better visibility into safety-system performance and stoppages can help determine the root cause of shutdowns. Safety and production data also can be combined to understand the frequency, duration, time and location of safety-related shutdowns. SAFETY INPUTS DESIGN TOOLS SAFETY LOGIC CONTROLLERS CONNECTION SYSTEMS LEGISLATION & STANDARDS GUIDANCE SAFETY OUTPUTS SAFETY SERVICES Improve compliance The safety data required for compliance and reporting purposes is largely collected through time-consuming, error-prone manual audits today. By integrating auditing functions into the HMI and controller, organisations can automate and speed up the auditing process, free up personnel to focus on other priorities, and reduce the likelihood of errors. Smart Safety 5

6 Scenario 1 Remote troubleshooting with Smart Safety Safety device performance communicated over EtherNet/IP Predictive maintenance routines established from historical data EtherNet/IP network allows standard and safety data to be captured on individual device operation Simplifies wiring and system complexity All time stamped data of device operation available in FactoryTalk Historian Light curtain has buildup of dirt reducing sensing field. 2. Machine operator quickly informed which light curtain has an issue Machine operator cleans the light curtain, preventing unnecessary machine downtime. 4. All smart devices on the machine give current status information to operator, where and when it is needed All device interactions are captured in system. Data can be used for predictive maintenance plans. 6. Machine working efficiently and with predictive maintenance planned. Visit to see how Smart Safety can make the difference Smart Safety 6

7 Scenario 2 Request safe access over EtherNet/IP network Guard position, lock status and access request managed over standard unmodified ethernet (Safety over EtherNet/IP) Historical data of access request can be used for application adjustments Simplified network architecture for standard and safety control Add-on profile in Studio 5000 provides simplified setup and monitoring Indication given separately for guard door position and guard lock status Box falls from pallet in shrink wrapper due to speed of conveyor System checks for safe condition and then grants access. Access approval logged in system. 2. Machine operator requests safe access via smart safety interlock device. Request action logged in system. 4. Machine operator safely enters machine and replaces fallen box Machine operator closes guard door, initiates a reset request which locks the guard closed. Request logged in system. 6. All data logged in system is available to enable machine performance adjustments. Visit to see how Smart Safety can make the difference Smart Safety 7

8 Scenario 3 Machine uptime from Smart Safety data Access frequency into the machine through individually identified access points, is available with Smart Safety Smart Safety allows data to be captured on individual device operation Simplifies wiring and system complexity Smart Safety can be used with your existing safety devices Historical data of access request can be used for application adjustments Tape from supplier frequently breaking. 2. Machine operator opens interlocked guard door to fix tape. Device operation is logged in system Machine operator restarts machine. 4. Production manager has all data available on safety device actions Production manager and machine operator discuss reason of frequent access. Tape causing problem can be replaced. 6. Machine running more efficiently with less maintenance required. Visit to see how Smart Safety can make the difference Smart Safety 8

9 Scenario 4 Predictive maintenance with Smart Safety solution Smart Safety allows predictive maintenance procedures to be adopted based on device use or age Smart Safety allows data to be captured on individual device operation Simplifies wiring and system complexity Smart Safety can be used with your existing safety devices Historical data of access request can be used for application adjustments Operations of safety devices per shift are captured. 2. All safety device operational use from manufacturing line available Monitoring number of operations helps predict when device is at end of life. 4. Information is available for maintenance staff to replace device Device can be replaced at next planned maintenance schedule. 6. Machine downtime reduced to a minimum. Visit to see how Smart Safety can make the difference Smart Safety 9

10 3 pillars of support for your safety requirements The right products Rockwell Automation has the broadest portfolio of any machinery safety solutions supplier, and can provide all three parts of a safety system. Safety input devices Presence-sensing safety devices Safety interlock switches Emergency stop & trip devices Operator interface Safety logic controllers Safety relays Configurable safety relay Integrated safety controllers Safety I/O devices Safety actuators Safety contactors PowerFlex AC drives Kinetix integrated motion Connection systems/networks Quick connect connection systems Safety over EtherNet/IP GuardLink linking technology The right tools A wide range of tools that support compliance with safety standards, reduce the risk of injuries and improve productivity. Safety Automation Builder FREE software tool to help simplify machine safety design and validation, reducing time and costs. Integration with RASWin Risk Assessment Software provides you with consistent, reliable, documented management of the Functional Safety Lifecycle. SISTEMA integration The SISTEMA tool automates calculation of the attained Performance Level outlined in (EN) ISO Data is available to be used with the SISTEMA calculation tool. Helps users in the design stage Comprehensive Rockwell Automation database Pre-engineered Safety Functions Machine safety can be developed by combining blocks of safety functions. Our preengineered safety functions come with a SISTEMA Performance Level calculation as outlined in (EN) ISO Reduces design times Includes set-up, wiring, configuration and validation information Complete bill of materials Accelerator Toolkits Easy to use system design, programming, and diagnostic tools to assist in the rapid development and deployment of safety systems. Reduces design time and risk Smart Safety 10

11 The right people A comprehensive range of safety services and support is available from both Rockwell Automation and its machinery safety certified Recognised System Integrator partners. TÜV Rheinland certified machine safety training courses Helping deliver staff training that qualifies towards an industry-standard TÜV Rheinland Certificate, enabling trainees to understand safety requirements and compliance. Risk Assessment Service Rockwell Automation s global safety team of consultants and partners can assist end users, integrators and OEMs at any step of a safeguarding project. Comply with safety standards to reduce the risk of injuries and improve productivity. Trained staff and partners Rockwell Automation has TÜV Rheinland machinery safety qualifications it requires its employees and partners to achieve in order to support you. Leverage their knowledge now. Knowledge of automation and safety The benefit of partnering with Rockwell Automation is you gain the support and expertise of people who understand automation and safety, not just safety. Smart Safety 11

12 Rockwell Automation, Inc. (NYSE:ROK), the world s largest company dedicated to industrial automation, makes its customers more productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley and Rockwell Software product brands are recognised for innovation and excellence. Follow ROKAutomation on Facebook, Twitter and Google Plus. Subscribe to us on Youtube. Connect with us on LinkedIn. Allen-Bradley, LISTEN. THINK. SOLVE., Rockwell Software, Studio 5000 and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Publication SAFETY-BR002A-EN-P July 2017 Copyright 2017 Rockwell Automation, Inc. All Rights Reserved.