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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC
PUBLIC - 5058-CO900H
Ensuring Machinery Safety, Compliance, and Productivity.
PackExpo - September 2015
George Schuster
Global Safety BusinessSteve Ludwig
Program Manager, Safety
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Agenda
Summary
Is This Machine Safe?
Design Philosophies for Systematic MTTR Reduction
Functional Safety Lifecycle
The Safety Landscape, Tools for Functional Safety
Challenging Perceptions
Risk, Value, and Safety Maturity
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 3
Challenging Perceptions
Bill Hilton, Director of Health and Safety
“A historical lack of accidents does not imply a
current presence of safety. It simply means
you’ve been faster than the machine.”
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Challenging Perceptions
4
“I will say that I cannot imagine any condition which could cause a ship to founder. I cannot conceive of any vital disaster happening to this vessel. Modern shipbuilding has gone beyond that.”
- Captain EJ SmithCaptain, HMS Titanic
“What a strange sense of logic to fixate on the absence of something (injury) as a demonstration of the presence of something else (safety). Such a proposition misunderstands the dynamic of risk and being human.”
“Measuring safety by the number of injuries is like measuring parenting by the number of smacks you give.”
– Dr. Robert Long, 2014 Human Dymensions
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
What if?
• Reduce Injury Rate by Half
• Increase Overall Equipment Effectiveness (OEE) 5%-7%
• Reduce Unscheduled Downtime 2%-4%
Best-In-Class Performance
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Business Risks
7
• Aging Workforce• Retiring workers
• Loss of skills and knowledge
• Unfilled jobs
• Inexperienced workers at higher risk
• 40% reduction in productivity growth
• Supply Chain Interruption Causes• Accidents #1
• Production #2
• Labor availability #3
• Financial loss and premiums #6
• Regulatory #8
• Lawsuits #10
• Reputational / Brand Risk• Worker treatment / injuries
• Environmental
• Labor
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
• 5%-7% Higher OEE
• 2%-4% Less Downtime
• <50% injury rate
Business Value
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 99
Safety Maturity
Culture (behavior): The company DNA from upper
management support, cross-functional safety teams,
observable.
Compliance (procedure): Established risk
management processes, procedures, and standards
to identify, prioritize and mitigate risks
Capital (technology): Investments in technologies
that improve both safety and productivity.
Contemporary safety solutions and technologies are
seen as a viable investment with an ROI.
Safety Safety Life CycleLife Cycle
5. Maintain & Improve1. Hazard or Risk
Assessment
4. Installation & Validation
2. Functional Requirements
3. Design & Verification
Safety Safety Life CycleLife Cycle
5. Maintain & Improve1. Hazard or Risk
Assessment
4. Installation & Validation
2. Functional Requirements
3. Design & Verification
What differentiated Best-in-class Manufacturers from their Peers?
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 10
Good Companies: Safety = Cost Savings/Avoidance
Great Companies: Safety = Performance
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 12
Source – Rockwell Automation, 2013 Manufacturing Safety Effectiveness Study
by The Aberdeen Group
15%
23%
37%
25%
Level
SMI4 SMI3 SMI2 SMI1
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
New Safety Landscape
• Design-In Safety - a Core System Function
• Safety as a Core Machine Value: Global Compliance
Common Designs
Reduced Costs
Increased Efficiency –
Systematic MTTR Reduction
Improved Competitiveness
Reduced Floor Space; Reduced Labor
Improved Ergonomics; Reduced Injuries
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
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?
Safety must be Easy and Intuitive
• Are Safety Systems or Technologies ever
Bypassed?– Are people using a “Cheater Key”?
– Some systems are so poorly designed and
integrated that maintenance people are forced to
bypass the safety system just to get their jobs done!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Tools for Functional Safety
Emergence of Global Specifications
Standard Machine Designs that are Globally Compliant
ISO 13849; IEC 62061
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 © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Functional Safety Life Cycle
Functional Safety Life Cycle
ISO 13849
5. Maintain & Improve
1. RiskAssessment
4. Installation & Validation
2. Functional Requirements Specifiation
3. Design & Verification
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 18
Risk Assessment – The Foundation
• A “Task-Based” , Team Approach – Builds Consensus, Repeatable
• Provides Safety Performance Level – Design Target
• Creates the Foundation of the Safety System Functional Requirements, System Design and
Validation Protocols.
• Shows “Due Diligence” and Global Compliance (Ref. ISO 12100, 14121)
S1
S2
F2
F1
Performance
Level, PLr
a
b
P1
P2
e
c
d
P1
P2
P1
P2
P1
P2
F2
F1
S = SeverityF = Frequency or Duration of ExposureP = Avoidance Probability
Task/Hazard
Contribution
to Risk
Reduction
Low
High
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
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 19
Design Philosophies – Systematic MTTR Reduction
• 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 and
improve Efficiency.
Safety AND Productivity
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Improved Productivity by Design:Systematic MTTR Reduction
RunningDown
Ma
ch
ine
Sto
ps
Ma
inte
na
nce
Arr
ive
s
Fa
ult Id
en
tifie
d
LO
TO
Re
pa
ir P
erf
orm
ed
Mach
ine U
nlo
cked
Re
pa
ir T
este
d
Ma
ch
ine
ba
ck in
Au
to
Pro
du
ctio
n R
esu
me
s
MTTR = 12 minutes (avg.)
Running
Typical Downtime Event
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Is This Machine Safe?
Was a Risk Assessment Performed
Cross-functional Team-based?
All Task/Hazard Pairs Evaluated?
All Operating Modes Considered?
Target Risk Reduction Levels Identified?
Mitigations Evaluated and Outlined?
Residual Risk Recorded?
Documentation Completed?
Risk Assessment is the Foundation
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Is This Machine Safe?
Was a Safety Functional Requirements Specification (SFRS) Created?
Detailing Span of Control for all Safety Functions (SF’s)?
All Operating Modes Considered?
Behavior under Faults and Failures Documented?
All Use Cases Mapped?
SFRS Defines the Safety System Requirements
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Is This Machine Safe?
Has the Engineering Design been Verified?
Verification plan Generated?
All SF’s Reliability Modeled?
All Safety Component Data Recorded?
SF’s modeled for Structure (Cat.), Reliability (MTTFd), Diagnostic
Coverage (DC) and Common Cause Failures (CCF)?
Results Compared to PLr requirements from the Risk Assessment?
Results Documented, Report Generated?
Reference SISTEMA for ISO 13849
http://www.dguv.de/ifa/Praxishilfen/Software/SISTEMA
Verification Helps Ensure No Design nor Specification Errors
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Is This Machine Safe?
Has the Build and Installation been Validated?
Validation Plan Created? Escalation Plan?
Includes Functional and Fault Injection Tests?
Includes all Modes of Operation?
Tests all Field Devices?
Results Documented, Report Generated?
Validation helps ensures no Errors during Build/Installation
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC
Summary
Safety Maturity Index
Achieving Operational Excellence
New Tools for Functional Safety
The Functional Safety Lifecycle is your guide
New Design Philosophies – Systematic Reduction of MTTR
Is this Machine Safe? Things to check!
Risk Assessment?
Design Verified?
System Validated?