CSA/IAPA, Toronto June 4-5, 2007

Transcription

1 CSA/IAPA, Toronto June 4-5, 2007 Jeff Mathyssen Canadian Safety Business 1

2 Agenda Programmable Safety Overview Safety & Maintenance Sample Machine Servicing Sequence Time Savings Example(s) 2

3 Technology Innovations in Safeguarding Products New or enhanced sensing technology Electronic / microprocessor-based technology Solid-state output technology New connection and wiring termination technology Safety networking technology Integration of safety technology into standard automation products PLC s, Programmable Automation Controllers (PAC), AC drives and Servo drives Rapid adoption of popular standard automation technologies IP67 or stainless steel packaging, OPC communications, etc Sensors Logic Control Actuators New technology innovations are enabling improved safeguarding strategies, critical to to effective functional safety implementation & increased productivity Making the safety system easier to to implement and more flexible in in addressing operator & maintenance procedures Making safety systems cost effective to to automate, enables increased productivity 3

4 Safety Control System Platforms Dedicated Safety Relays and Control Units Basic historical building block for safety control inter-wired to create basic logic Electro-mechanical, more sophisticated units are now solid-state Expandable Safety Relay Controllers (ESRC) More cost effective alternative to individual safety relays inter-wired Very cost-effective to individually monitor safety devices & networking for diagnostics Safety PLCs Same value proposition as standard PLC s; simple user interface, etc. Multi-purpose safety controller enabling more sophisticated control options via logic programming and networking capabilities Integrated Safety - Programmable Automation Controllers (PAC) PACs are a common control platform for sequential, motion, drive, process and safety control applications Ultimate solution for integration of machinery safety and standard automation 4

5 Technology Changes in Safety Products PRIOR CAPABILITY Electro-mechanical safety devices Dedicated functionality Device/Sensor specific relays or controllers Fixed I/O configurations Limited diagnostics Electro-mechanical relay outputs Monitoring via hard-wiring into standard PLC I/O PRESENT CAPABILITY Microprocessor- based sensors, logic or actuators Multi-function with application specific functions Configurable or programmable controllers (PLC or PAC) Expandable I/O or remote I/O via safety networking Robust diagnostics and security features Solid-state outputs Monitoring via network connectivity 5

6 How did people control different applications? You often had to use different kinds of control systems for different applications: PLC s for sequential control DCS systems for process control Safety PLC s or components for safety control Motion controllers for motion control Drive systems for drives control 6

7 Today, One Control Platform Today s Safety Controller Software has Function Block Diagram, Ladder Logic, Structured Text, Sequential Function Chart, and Certified Safety Instructions. These core editors with specialized motion, process, safety and drives control instructions provide you the tools to effectively use a range of controllers for all of your applications. sequential control safety control process control motion control drives control 7

8 Trends Notice the similarity between Relay Controls, PLC s and Networks 1980 s Today 8

9 Benefits of Programmable Safety Control Safety Control Systems Can Increase Productivity & Profits Provide operators with equipment that allows them to work productively while minimizing their risk of injury to a reasonable level... reduces the likelihood of overriding safety subsystems Provide engineers and maintenance personnel with contemporary safety control systems that are designed to provide design flexibility and increased diagnostics reduces life-cycle design, start-up, and Mean Time to Repair costs and increases the likelihood that Standard Operating Procedures will implemented Safety Control Systems should be designed with all the life cycle phases evaluated up front Increasingly intelligent safety control systems are enabling a fundamental change in how safety is viewed in manufacturing 9

10 Example Processor Structure of a Safety PLC with 1oo2D 10

11 Example Safety I/O Structures - Output Module Output Module 11

12 Example Safety I/O Structures - Input Module Input Module 12

13 Programmable Safety Environment Safety Controller Status Safety Instruction Palette Periodic Safety Task Routine Information Box with Class Watermark for Safety Editing Screen 13

14 Typical Safety Certified Instructions 49 Safety Certified Instructions Subset of standard ladder logic instruction set 7 Safety Certified Application Instructions Provide 14 Safety Functions ESTOP Emergency Stop DIN Diverse Input RIN Redundant Input ROUT Redundant Output LC Light Curtain ENPEN Enable Pendant FPMS Five Position Mode Selector 14

15 Networked Safety System Safety Controller System Capabilities Safety Interlocking and control via CIP Safety over ControlNet or EtherNet/IP EtherNet CIP Safety EtherNet I/P CIP Safety ControlNet CIP Safety DeviceNet 15

16 Safety PLC and Security Safety controllers can have many security options Project based security features Safety related security options Routine security Plant wide based security options 16

17 Change Management Audits 17

18 Safety PLCs and Networks - Summary Variety of Safety Controllers to Meet Diverse Application Requirements Packaged and Modular High Performance, High Reliability Focused on Ease of Use - Superior Programming Software Functionality High Performance Safety Networking Options DeviceNet Safety (2005), EtherNet/IP Safety (2007) Support of Distributed Safety I/O or Distributed Logic Support of High Speed Ethernet Back-bone Cell to Cell, processor to processor Flexible Architecture - Variety of Integration Options Integrated Networking - Standard and Safety CIP Safety is the key enabling technology Integrated Control - Standard and Safety Safety can be Integrated 18

19 Safety & Maintenance Question: : Why is safety important to maintenance? Safety is all about making it safe for employees to work around equipment Equipment can be particularly dangerous for maintenance activities Must often work in the hazardous areas of the machinery May often work out-of-sight of other employees Can be seriously injured if the machine is unexpectedly energized 19

20 Operation vs. Maintenance The principles of machine guarding are different for Operators and Maintenance Operator Safety Goal: Protect the operator from inadvertent injury from equipment hazards Protection from: Rotating hazards, nip points, flying chips or sparks, etc. Protected by: Barrier guards, hard fencing, electronic safety devices, two-hand controls, pull back mechanisms, etc. Maintenance Safety Goal: Protect maintenance from unexpected start-up of the equipment while enabling them to complete their function Protection from: Unexpected energization Protected by: Safe working practices and procedures 20

21 Maintenance and Productivity Question: : What is the relationship between Maintenance and productivity? A key metric for any Maintenance organization is Mean Time to Repair (MTTR) In Production MTTF Out of Production Start Unplanned Downtime Event Recovery and Restart In manufacturing, MTTR is a measure of how quickly a machine can be restored to production The faster that a machine can be restored to production, the more productive the machinery will be MTTR 21

22 Maintenance and Productivity Question: : How much does MTTR cost? MTTR is unplanned downtime Customers measure cost of downtime in many ways Opportunity cost of lost production Overtime costs associated with recovery Maintenance cost variance MTTR Cost = MTTR * Cost of Downtime Facility overhead Penalty payments Customer satisfaction Example: In a given year, a piece of equipment experiences 40 hours of unplanned downtime at an opportunity cost of $50 / Minute MTTR Cost = 40 hrs. * 60 min/hr. * $50/min = $120,000 QUIZ: What if there are 100 machines in the plant? 22

23 Service Activities Question: : What are maintenance activities around a machine? There are a variety of customer activities that fall under the definition of maintenance or servicing Installing Setting Up Inspecting Adjusting Repairing Replacing Constructing Modifying Maintaining Lubricating Cleaning Unjamming Adjustments or Tool Changes NOTE: : Some of these tasks may actually be performed by the machine operator. We will refer to all of these tasks as servicing from this point onward. 23

24 Example Sequence of a Repair Operation Question: : What contributes to MTTR? In an unplanned downtime event, there are a variety of servicing steps that may take place Unplanned Machine Stop Operator determines source of of stop Call Maintenance Initial Inspection / / Fault Identified Decision to enter Hazardous Area Lockout / / Tagout Enter Hazardous Area Repair performed Exit Hazardous Area System Unlocked Repair Tested Machine back in in Auto Production Resumes 24

25 Using Safety to Improve MTTR Question: : How can safety improve MTTR? Contemporary safety methodologies can improve MTTR by shortening the steps required to identify, repair and restore the equipment to the production state Identify: Be able to quickly determine why a machine stopped and the source of the problem that needs to be repaired Repair: Be able to quickly access the machinery that needs to be repaired while providing the appropriate level of protection Restore: Be able to rapidly return the system to its optimum production state 25

26 Note Equipment will experience an unplanned downtime event for various reasons Process automatically halted due to equipment malfunction (example: misaligned sensor, parts jam, component failure) Process manually halted due to process failure (example: ejected part, material spill, ) Process automatically halted because of a failure of a control system component (sensor breaks, pulse test fails, E-Stop erroneously triggered) Frequent Big $$$ Savings Less Frequent Highly Aggravating Regardless of the type of failure, if the service provider requires access to the machinery then safety practices are required The example sequence in in this presentation is is a generic methodology not all of of the steps in in the sequence will apply to to every situation 26

27 Determining the source of a stop Unplanned Unplanned Machine Stop Operator Operator determines source of of stop Initial Inspection / / Fault Identified Access Equipment Repair performed System Unlocked Repair Tested Machine back in in Auto Production Resumes 27

28 Determining the source of a stop When a machine stops, it may not be obvious to the operator as to why it stopped Was there a jam? Was there a component failure? Was there a demand on the safety system? Was there a failure of a safety component? etc. The operator will spend some amount of time determining if maintenance should be called This time can vary more depending on the complexity of the machine and the training of the operators 28

29 Determining the source of a stop Standard PLCs use HMI s to provide system status information to operators and maintenance Traditional hard-wired safety systems are more difficult to troubleshoot Stand-alone (visual LED diagnostics only); or Auxiliary contact on safety device is wired to the standard PLC Very limited diagnostics on / off or faulted status only Application Logic Auxiliary Inputs 29

30 Determining the source of a stop Hardwired E-Stop #1 E-Stop #2 E-Stop #3 E-Stop #4 Out Feed Conveyor In Feed Conveyor E-Stop #5 Safety Relay If there were a short circuit between E-Stops #2 and #3 what would the operator know? Safety relay will de-energize its outputs will be picked up by standard PLC input Did someone hit and E-Stop? Did the circuit fail?... Operator must walk to the panel and try and interpret the LEDs How long does this take? 30

31 Determining the source of a stop Safety PLCs / Safety I/O can provide detailed diagnostics that can be immediately made available to the operator or to maintenance personnel Data can be provided to the Safety PLC, the Standard PLC or direct to the HMI For an operator the source of the stop can be readily identified Process stop misaligned part, tool jam, gate opened, etc. Safety System Error Failure of safety component, Wiring error detected Operator can quickly determine where the machine stop came from and what action to take Entire safety system can be monitored by the Safety PLC and viewed on the HMI EtherNet/IP DeviceNet * Single Safety I/O module can be wired to up to 8 dual channel input devices 31

32 Initial Inspection / Identify fault Unplanned Unplanned Machine Stop Operator Operator determines source of of stop Call Maintenance Initial Initial Inspection / / / Fault Identified Access Equipment Repair performed System Unlocked Repair Tested Machine back in in Auto Production Resumes 32

33 Inspection / Fault Identified A safety relay will de-energize in the case of a fault Recall this example hard-wired example E-Stop E-Stop E-Stop E-Stop Out Feed #1 #2 #3 #4 Conveyor In Feed E-Stop Conveyor #5 Safety Relay Safety PLC Systems can provide a tremendous amount of diagnostic information to operators and maintenance Wiring faults including short to ground, short to +24V and channel-to-channel shorts, etc. Detailed I/O diagnostics including input unable to change state, output unable to change state, inputs inconsistent, outputs inconsistent (from the program logic), etc. PLC Diagnostics including user program memory error, firmware memory error, (both usually caused by noise), watchdog timeout (i.e. prevent "blue screen of death"), power supply failure/problem, etc. 33

34 Inspection / Fault Identified Programming Software for Safety PLCs provides a number of tools that can assist in the troubleshooting phase, including: Remote Programming & Troubleshooting Access Trending Tools (w/triggers) I/O Forcing Application Emulation Filtering Latching 34

35 Initial Inspection / Identify fault Unplanned Unplanned Machine Stop Operator Operator determines source of of stop Initial Initial Inspection / / / Fault Identified Access Lockout Equipment / / Tagout Repair performed System Unlocked Repair Tested Machine back in in Auto Production Resumes 35

36 Access Equipment When an employee requires access to the hazardous area of equipment, the equipment must be made safe for them to do so This requirement is common to all safety standards (US, EMEA, Canada, Australia, Japan, etc.) Different countries have different standards that regulate the requirements for securing the hazardous areas In this presentation, we will use the US OSHA standards as an example 36

37 Operation vs. Maintenance The principles of machine guarding are different for Operators and Maintenance Operator (Production) CFR Safety 1910 Subpart Goal: O Machine Protect Guarding the Protect operator employee from from inadvertent exposure to hazards injury during normal production operations from equipment hazards Requires guarding to protect operators from hazards Protection from: Rotating hazards, nip points, flying chips or sparks, etc. Protected by: Barrier guards, hard fencing, electronic safety devices, two-hand controls, pull back mechanisms, etc. Maintenance (Servicing) Safety Goal: Protect maintenance from unexpected start-up of the equipment while enabling them to complete their function Protection from: Unexpected energization Protected by: Safe working practices and procedures CFR Lockout / Tagout Protect employee from unexpected energization of the equipment Requires physical disconnect of all energy sources 37

38 What is Lock Out Tag Out? A process where service and maintenance personnel can prevent unexpected energization of equipment by releasing all stored energy Lock Out Tag Out requires the affected individual(s) to: Turn off / disconnect all energy sources to the equipment before performing service and / or maintenance Use a lock to secure the energy sources in the off state Use a tag to identify the individual performing the service and warn others to not attempt to reenergize the equipment while he or she is servicing it 38

39 Lock Out Tag Out Example Procedure Event Event Requiring Access Access to to Equipment Equipment Returned to to Production Acquire Lock Box Notify Employees of of Shut Down Disconnect Energy Sources Verify Removal of of Energy Perform Task(s) Restart Equipment Notify Employees of of Equipment Restart Restore Energy Sources / / Remove Locks Verify that No Employees in in Hazardous Area Remove Tools from Work Area Energy sources could include: Electrical Pneumatic / Hydraulic Mechanical (Gravity) Chemical Thermal (Steam) Mechanical (Inertia) 39

40 Benefits Lock Out Tag Out Pros and Cons Very safe removal of energy guarantees no unexpected motion Very secure application of locks prevents unexpected energization Very personal tags identify who is in the hazardous areas Drawbacks Can be time consuming if service is minor Employees may choose to bypass if procedures are perceived to be burdensome and risk is perceived to be minor Certain servicing may require limited energy (robot teach, re-adjust partpresent switch on gripper, adjust / change tool, etc.) 40

41 Minor Service Exception to Lockout Tagout OSHA recognized the limitations of Lockout / Tagout and provided an exception in CFR for purposes of minor servicing Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, are not covered by this standard if they are routine, repetitive, and integral to the use of the equipment for production, provided that the work is performed using alternative measures which provide effective protection (Reference Subpart O Machine Guarding). This paragraph generally known as the Minor Service Exception to Lockout Tagout 41

42 Minor Servicing Activities What are examples of Minor Servicing? This must be decided by your customers based on the function of their machinery The following activities could potentially qualify as minor servicing: Parts jam in hazardous area Photoswitch out of alignment Ejected (or dropped) part in a robot cell Cleaning of printing rolls during operation Visual inspection of hazardous area The concepts associated with the Minor Servicing exception fall into the domain commonly referenced as Alternative Means to Lockout Tagout 42

43 Alternative Means to Lockout Tagout The opportunity to simplify access to equipment is (easily) the most significant productivity benefit available to customers Employees access the machine for minor servicing operations at a very high frequency Clear a Jam Clean a spill Handle ejected part Load Parts etc. On frequent applications, the time savings for routine access to a machine can be significant 43

44 Food Palletizing Application Lockout Tagout Service Entrance Conveyor Power Exit Conveyor Robot Pallets Slip Sheets Pallet Load Gates Overhead Entry Conveyor Exit Conveyor Pneumatic Power Robot Power Shipping Pallets replaced every 60 minutes Lock & Unlock procedure takes 90 seconds 5 pallets / hour 90 seconds = 0.3 pallets 1 pallet = $1,000 profit $300 / hour lost production $2,400 / shift $1.2 Million per year! 44

45 Food Palletizing Application Lockout Tagout Service Entrance Conveyor Power Exit Conveyor Pallet Load Zone Robot Pallets Slip Sheets Pallet Load Gates Overhead Entry Conveyor Control Panel Exit Conveyor Shipping Operator uses Control Panel to select Load Pallet mode Robot is restricted to Pallet Load Zone If Robot travels out of Pallet Load Zone power is removed and motion is stopped Pneumatic Power Robot Power Pallets can be loaded without any requirement for Lockout Tagout Pallet Load gates held shut with Guard Locking switch unless Load Pallet mode is selected 45

46 Food Palletizing Application Product Spill Service Entrance Service Entrance Conveyor Power Exit Conveyor Robot Pallets Slip Sheets Overhead Entry Conveyor Control Panel Pallet Load Gates Exit Conveyor Shipping Occasionally (1-2/shift), the robot will drop a carton or glue will cause carton to open Resulting spill must be cleaned up Operator can request access to cell and use a personal lock to prevent unexpected energization Pneumatic Power Robot Power Operator can the clean spill without a full Lockout Tagout NOTE: This will eliminate Lockout Tagout for this procedure but not the restart sequence A motion detect switch could be used on the robot to monitor motion, allowing operator to enter cell without removing power to robots 46

47 Repair Performed Unplanned Unplanned Machine Stop Operator Operator determines source of of stop Initial Initial Inspection / / / Fault Identified Access Lockout Equipment / / Tagout Repair performed System Unlocked Repair Tested Machine back in in Auto Production Resumes 47

48 System Unlocked Unplanned Unplanned Machine Stop Operator Operator determines source of of stop Initial Initial Inspection / / / Fault Identified Access Lockout Equipment / / Tagout Repair performed System Unlocked Repair Tested Machine back in in Auto Production Resumes 48

49 System Unlocked / Tested Once a repair has been performed, it must be tested to confirm that the system has been restored to working order This will require that power be restored to the system The system must then be unlocked so that the machinery can be tested Basically the reverse of the Lockout Tagout process Event Requiring Event Requiring Access to Access to Equipment Equipment Acquire Acquire Lock Lock Box Box Notify Notify Employees Employees of of Shut Shut Down Down Equipment Equipment Returned Returned to Production to Production Restart Restart Equipment Equipment Notify Notify Employees Employees of of Equipment Equipment Restart Restart Disconnect Disconnect Energy Energy Sources Sources Verify Verify Removal Removal of of Energy Energy Perform Perform Task(s) Task(s) Restore Restore Energy Energy Sources Sources / / Remove Remove Locks Locks Verify Verify that that No No Employees Employees in in Hazardous Hazardous Area Area Remove Remove Tools Tools from from Work Work Area Area 49

50 System Unlocked / Tested If the machine repair did not work properly then the machine must be re-locked and re-worked Event Requiring Event Requiring Access to Access to Equipment Equipment Acquire Acquire Lock Lock Box Box Try Again! Equipment Equipment Returned Returned to Production to Production Restart Restart Equipment Equipment Notify Notify Employees Employees of of Shut Shut Down Down Disconnect Disconnect Energy Energy Sources Sources Verify Verify Removal Removal of of Energy Energy Perform Perform Task(s) Task(s) Notify Notify Employees Employees of of Equipment Equipment Restart Restart Restore Restore Energy Energy Sources Sources / / Remove Remove Locks Locks Verify Verify that that No No Employees Employees in in Hazardous Hazardous Area Area Remove Remove Tools Tools from from Work Work Area Area Even more downtime! 50

51 Machine Back in Automatic Unplanned Unplanned Machine Stop Operator Operator determines source of of stop Initial Initial Inspection / / / Fault Identified Lockout / / Tagout Repair performed System Unlocked Repair Tested Machine back in in Auto Production Resumes 51

52 Machine Back in Automatic A hard E-Stop, where power is immediately removed from the machinery, can be a difficult and time consuming event to recover from Work-In-Process may have to be cleaned, removed, reset or scrapped Robots and Motion devices may need to be re-homed Certain machinery may need to be re-initialized Wear & Tear to machinery and control devices 1. Gate Opened Homing Service 3. E-Stop 4. Scrap Operation Gate Generated Removed Closed Performed by Safety System 52

53 Machine Back in Automatic A hard E-Stop, where power is immediately removed from the machinery, can be a difficult and time consuming event to recover from Work-In-Process may have to cleaned, removed or reset Robots and Motion devices may need to be re-homed Certain machinery may need to be re-initialized Wear & Tear to machinery and control devices 6. System Restarted 53

54 Machine Back in Automatic Integrating Safety and Standard Control systems can greatly improve restart times End of Cycle Hold in standard PLC Bring machine to a graceful halt Complete critical processes Cycle Work-in-Process out of cell When end of cycle reached, safety system is engaged and entrance is granted Limited scrap and re-work Re-start much faster since motion axes in home position Limited wear & tear on production equipment 1. Cycle Hold Requested Standard PLC 3. halts Service 5. process, 2. System 4. Operation Gate cycles Opened Closed Restarted Performed out work-in-process, motion axes return to home 54

55 Production Resumes Unplanned Unplanned Machine Stop Operator Operator determines source of of stop Initial Initial Inspection / / / Fault Identified Lockout / / Tagout Repair performed System Unlocked Repair Tested Machine back in in Auto Production Resumes 55

56 How to Justify When should you consider streamlining service procedures? The cost justification is based on the amount of time savings that can be achieved and the measurable cost of downtime Streamlining service procedures make sense when: Service is routine, repetitive and integral to the operation Frequent access to the machine is required for minor servicing activities Lockout Tagout is time consuming and cumbersome (and prone to bypass) The measurable cost of downtime is high 56

57 How to Improve How do you go about streamlining maintenance activities? The most productive safety systems start with the machine design Design safety in from the beginning Partner with your machine suppliers (OEM, Integrator) Understand the hazards inherent to the machine and the task that operators perform Risk Assessments are KEY Have documented safety policies that account for Functional Safety (In United States) Consider Using ANSI Z244.1 as a program/policy guide Incorporate the appropriate legislative and industry standards Safety is a great candidate for a Six Sigma / LEAN project 57

58 Safety Innovations are Enabling Increased Productivity In Lean Manufacturing Improved Machinery Safety A safer machine Leveraging new standards and products, implementing new processes A more confident & empowered workforce A more productive environment Lower overall operational costs tied to safety programs Cost effective risk management Indirect costs can be 3x direct costs Reduced loss work time, reduced workers compensation insurance costs Improved Productivity / Lower Total Cost of Ownership Reduced time to design, install and start-up Reduced space requirements floor space and panel space (Lean) Reduced mean time to repair (MTTR) Increase in overall equipment effectiveness (OEE) OEE = Availability (downtime) x Performance (speed) x Quality (reject x rework) Improved overall production throughput and asset utilization Improved Safety Design Processes Coupled with Intelligent Safeguarding Products are Enabling Increased Productivity in in Lean Manufacturing 58

59 Modern Safety Thinking It s a Culture; It s a Process; It s a design Philosophy It is a combination of people systems (procedures) and technologies (components, circuits) It is a systematic approach Not a component approach!!! Machine Safety is like an anchor chain only as strong as the weakest link. It is a lifecycle from system concept, through Risk Assessment, Design, Build, Start-Up, Validation, Operations and Decommissioning Safety Specifications drive the Safety Lifecycle 59

60 Summary Safety is a shared responsibility we are all stakeholders! Every manufacturer must provide for a safe work environment. Well designed systems improve both Safety and Productivity. Safety is a System Solution not just components. Integrated into the control, information and people systems Safety is Specification Based. Leverage Internal and External application knowledge and expertise Maintenance, Engineering, Operations, Suppliers Single source full service safety supplier can help with comprehensive safety solutions. 60

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