Putting Performance in the Hands of Your People

Machine Safety Imperative The Time is Now

• Trends in Safety Standards

• Evolution of safety in manufacturing

Agenda

American Electricians’ Handbook, 5th ed., New York, McGraw-Hill Book Company, 1942, p 66

We Have Come a Long Way

US Standards

•Ensure Safe and Healthy Work Conditions •OSHA - The law “ have to comply” •States must meet or exceed •OSHA Regulations defined in Code of Federal Regulations Title 29 • Reference to Standards such as ANSI and NFPA

•Considered consensus standards. •Standards are Voluntary •Unless - they become part of the law •“Incorporated by Reference”

•ANSI – Coordinates Voluntary Standards •ANSI – Official representative to ISO/IEC •TUV – OSHA recognized NRTL

How OSHA Thinks About Machine Safety

1910.212(a)(1) Types of guarding. One or more methods of machine guarding shall be provided to protect the operator and other employees in the machine area from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips and sparks. Examples of guarding methods are: barrier guards, two-hand tripping devices, electronic safety devices, etc.

Part 1910: Occupational Safety and Health Standards

Subpart O: Machinery and Machine Guarding

1910.211: Definitions

1910.212: General Requirements for all Machinery

1910.213-190.219: Machine Specific Regulations

Subpart J: General Environment Controls

1910.147: The Control of Hazardous Energy (Lockout/Tagout)

1910.212(a)(3)(ii) The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefore, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.

1910.147(a)(2)(ii) The minor servicing exception provides that minor tool changes and adjustments and other minor servicing activities which take place during normal production operations may be exempt from the LOTO standard if the activity is routine, repetitive, and integral to the use of the equipment for production purposes, provided that the work is performed using alternative measures which provide effective employee protection.

Framework for U.S. Safety Standards

6

OSHA 1910.147 & OSHA 1910 Subpart O

Legislative Standards

NFPA 79

Electrical Standards

Mac

hin

ery

/ Ap

plic

atio

n S

tan

dar

ds

Sector Standards

Mechanical Press

Coil Slitting

Grinding

Etc.

Machine Tools S

emic

on

Am

use

men

t

Pac

kag

ing

Robots

Etc

.

Conveyors

RIA R15.06

ANSI B11.20

ANSI B11.9

ANSI B11.14

ANSI/ASME B20.1

ANSI B11.1

AN

SI /

PM

MI B

155.

1

SE

MI S

2

AS

TM

F22

91-0

4a

System Application Standards

• IEC 60204

• ISO 13849

• IEC 62061

Product Standards

• ISO 13856

• ISO 14119

• ISO 14120

• ISO 61800

• ANSI B11.1-20

•ANSI/PMMIB155.1

Source: Rockwell Automation

European Standards

• Goal to achieve free movement of goods and protecting its citizens •EU-Directives define:

•Basic product Requirements •Basic requirements for safe operation •Minimum requirements for safety at work •Technology neutral

•Standards Not Mandatory – is a legal obligation to keep to the EU-Directives •“Declaration of Conformity”

Machinery Directive

2006/42/EC

Work Equipment

2009/104/EC

Global Machine Safety Standard Convergence

Global Convergence

Three-tier Safety Standards Structure

Type A

ISO 12100 Safety of machinery. Basic terminology

and methodology

ISO 14121 Safety of machinery. Risk assessment

Type B

ISO 13849-1 - Safety related parts of control systems

ISO 13850 - Emergency stop function

IEC 62061 - Functional safety of electrical control

systems

IEC 60204-1 - Safety of machinery. Electrical

Equipment

ANSI/NFPA 79 – Electrical standard for Industrial

Machinery

Type C

EN 12012 – Safety requirements - Plastics and Rubber

machines

ISO 10218 - Safety requirements – Industrial Robots

ANSI/B155.1 - Safety Requirements for Packaging

Machinery and packaging-Related Converting

Machinery

EXAMPLES:

Type A

Fundamental safety standards applicable to all machine. Type A standards deal with basic concepts, principles for design, and general aspects.

Type B

Standard applicable to a wide range of machinery. Type B is divided into two categories: B1: Specific safety aspects (i.e., safety distance, surface temperature, and noise.) B2: Safety related devices (i.e., two-hand controls, interlocking devices, pressure sensitive devices and guards)

Type C Detailed standards applicable to a specific machine or a particular group of machines

Source: Rockwell Automation

Standard EN/IEC 62061

• Specific to the machine sector within the framework of EN/IEC 61508: gives rules for the integration of safety-related electrical, electronic and

electronic programmable control systems (SRECS)

does not specify the operating requirements of non-electrical control components in machine (ex.: hydraulic, pneumatic)

• The probability of failure associated to the required SIL (Safety Integrity Level) depends on the frequency of usage of the safety function to be performed

Safety of Machinery application

EN/IEC 62061

Standard EN/ISO 13849-1

• The Standard gives safety requirements for the design and integration of safety-related parts of control systems, including software design.

• The Risk Graph helps to determine the required PLr (Performance Level Required) of each safety function

Comparison of ISO 13849 and IEC 62061

• Globalization of Safety Control Standards – ISO/IEC • Increased focus on Safety Design to Improve Productivity • Merging of Standards. Ex. ISO 13849/IEC 62061 • Transition from Electro-Mechanical to Electronic Safety

Controls • Safety Technology Integrated into Standard Automation

Hardware • Integration of Standard Controls and Safety Controls • Addition of Configurable and Programmable Safety Devices • Addition of Safe Motion Technology • Safety Networks • Safety being transparent

Key Trends in Safety

Example: Evolution of Safety

Past

Today

Focus was solely On performance

Focus now includes Performance and safety

FUTURE PRESENT PAST

Evolution of Machine Safety

•Focus on Machine Productivity •Safety cumbersome •Safety often Bypassed •Increase Injury and Risks •Standards often not implemented •LOTO Only

•Focus on Machine Productivity and Safety •Use of safety rated devices •Increased focus on safety standards •Safety standards implemented and enforced •Better Diagnostics

•Focus on Machine Productivity and Safety •Integrated Safety •Intelligent safety devices •Productivity Enhancing

Evolution of Safety Solutions

FUTURE PRESENT PAST

•Integrated safety Functions •Wider use of Safety PLCs •Safety Networks

•Acceptance of Safety PLC for safety and non-safety functions •Wide range of safety devices available •Programmable Safety

•Separate Automation controls •Stand Alone Safety •Hardwire Safety •Standards behind technology

Evolution of Safety Standards

FUTURE PRESENT PAST

•Used only National Recognized Standards •ANSI B11 •NFPA 79

•Mix of national and global standards implemented and enforced •ANSI B11 •NFPA 79 •ISO 13849 •IEC 62061

•Global standards •ISO 17305 – Merging of ISO 13849 & IEC 62061 •Partnerships between IEC and ISO and ANSI

• Use of safety controls can increase productivity and profits Work productively while minimizing their risk of injury

Enable design flexibility and increased diagnostics

Increased likelihood that Standard Operating Procedures will be followed.

Make machinery safer and easier to operate and maintain

Reduce the motivation to bypass

Machine Safety Control

Safe Operations is Smart Business

“Improving our safety record is not only good for our employees – it’s good for our business. We have calculated that progress in lost-time cases and days lost saves the company approximately $30 million in direct costs each year.” Ford Motor Company 2010-2011 Sustainability Report

• Assessment standards make sure you identify and remediate hazards appropriately.

• Product standards give you the confidence that the technology is being built correctly.

• Application standards ensure the right technology is selected, installed, and used correctly.

• Performance standards ensure each safety device as well as the safety system is designed in a reliable manner.

• Validation standards makes sure everything was properly put together to ultimately reduce the risk

Standards and Technology Together

Questions

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