Machine Safety Protecting your Most Valuable Assets Putting - - PowerPoint PPT Presentation

Putting Performance in the Hands of Your People

Machine Safety

Protecting your Most Valuable Assets

• Safety – Protecting Your Assets
• Roadmap to Machine Safety
• Global CPG Case Study

Agenda

How do you define Safety

Define Safety

Safety – Freedom from unacceptable risk of physical injury or of damage to the health of people, either directly, or indirectly as a result of damage to property or to the environment.

• Culture of Safety
• Employee “Buy-In”
• Recognize the safety issues
• Implement practices and

procedures

• Employee Empowerment
• Safety Training

Are your Employees Safe?

Safety and Productivity

Invest in Safety Technology Establish Corporate Safety Program

39% 26% 18% 23%

Best in Class All Others

OEE: 5% - 7% Unscheduled Downtime: 2% - 4%

What is Machine Safety?

Machine Safety: Refers to safeguards that are applied to both machinery and the

• perators who work with them. Examples are interlocks that stop a motor if a

person gets too close, safety guards that cover moving gears and blades, as well as the more obvious safety goggles and protective clothing.

What is Functional Safety?

Functional Safety: is the detection of a potentially dangerous condition resulting in the activation of a protective or corrective device or mechanism to prevent hazardous events arising or providing mitigation to reduce the fight consequence of the hazardous event.

Roadmap to Machine Safety & Case Study

Safety Life Cycle for Machine Safety

Technology Transfer & Training

Polytron Proven Roadmap to Machine Safety

Risk Assessment

Hazard Audit

Define Design

Implement

Validate

Technology Transfer & Training REGULATORY AND SAFETY STANDARDS

SAFE MACHINE STATE

• Hazard Audit
• Risk Assessment

Proven Roadmap to Machine Safety – Risk Assessment

• Determine Limits
• Identify Hazards
• Estimate the Risk
• Evaluate the Risk
• Reduce the Risk
• Document the process

ISO 12100

Proven Roadmap to Machine Safety – Risk Assessment

Identification of Hazards

Proven Roadmap to Machine Safety – Risk Assessment

Risk Estimation

Proven Roadmap to Machine Safety – Risk Assessment

Risk Reduction

Engineering Controls

(Safeguarding Technology)

Awareness Means

(Personal Protective Equipment)

Training & Procedures

(Administrative Controls)

Protective Measures Eliminate the Risk

• Design It Out
• Process Substitution

Physical Guarding Examples

• Fencing or Barriers
• Fixed Covers
• Interlocks, Light Curtains, Safety Mats
• Monitoring Relays, Safety PLCs
• Signs, Warnings, Annunciation Lights
• Safety Glasses, Gloves & Footwear
• Work Procedures
• Lockout / Tagout (LOTO)

Most Effective Least Effective

• After safeguarding measures, the standard ISO

12100:2010 refers to complementary measures to further reduce the residual risks to an acceptable level through such measures as training, signage and warning equipment (i.e. Beacons).

Residual Risk: “Risk that remains after the protective measures have been implemented.”

Addressing Residual Risk

• Definition
• High level Design
• Project Plan

Proven Roadmap to Machine Safety – Definition

• Design/Engineering
• Safety Functional Design Specification (SFDS)
• Safety Design
• Hardware/Software Bill of Materials
• Installation bids (Electrical/Mechanical)
• Final Scope, Schedule, and Cost

Proven Roadmap to Machine Safety – Design/Engineering

ISO 13849-1

• Implementation
• Programming (PLC / HMI)
• Hardware / Software Procurement
• Installation and Verification
• Proper installation is key to the reliability of the entire system

Proven Roadmap to Machine Safety – Implementation

• Validation of safety system
• Manage Validation Process
• Safety Circuit/Function Validation

Proven Roadmap to Machine Safety – Validation

ISO 13849-2

Proven Roadmap to Machine Safety – Technology Transfer & Training

• Technology Transfer & Training
• Training Needs Analysis
• Training Documentation Development
• Training Facilitation
• Training Validation

• 2009 company implemented a Culture of Safety
• Safety goal – create a work environment that is fatality and incident free

by 2015

• Compliant with laws and regulations
• Employees are empowered to refuse to participate in any

action that is unsafe

• Strategy includes training for employees, contractors and

visitors

• Internal safety teams conducted risk assessments on all

manufacturing facilities.

Global CPG Manufacturer Case Study

Palletizer – Highest Risk Area

Identified highest risk areas and engaged Polytron to reduce hazards to their acceptable level

Global CPG Manufacturer Case Study – Risk Assessment

• Risk Assessment

Global CPG Manufacturer Case Study – Definition

• Risk Assessment
• Definition

Global CPG Manufacturer Case Study – Design

• Risk Assessment
• Definition
• Design

Global CPG Manufacturer Case Study – Design

• Risk Assessment
• Definition
• Design

Global CPG Manufacturer Case Study – Design

• Risk Assessment
• Definition
• Design

Global CPG Manufacturer Case Study – Design

• Risk Assessment
• Definition
• Design

Global CPG Manufacturer Case Study – Implementation/Verification

• Risk Assessment
• Definition
• Design
• Implementation/Verification

Before After

Global CPG Manufacturer Case Study – Implementation/Verification

• Risk Assessment
• Definition
• Design
• Implementation/Verification

Global CPG Manufacturer Case Study – Validation

• Risk Assessment
• Definition
• Design
• Implementation/Verification
• Validation

Global CPG Manufacturer Case Study – Training

• Risk Assessment
• Definition
• Design
• Implementation/Verification
• Validation
• Training

One year after safety implementation, improved overall productivity:

• Increase uptime from 70-75% to 80%-91%,

a 14-21% improvement

• Incorporated Speed improvement: increasing

throughput

• Controls more operator-

accessible – increasing safety

• Increased availability to

diagnostics

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Questions

35