The Roadmap to Machinery Safety Putting Performance in the Hands of - - PowerPoint PPT Presentation

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The Roadmap to Machinery Safety Putting Performance in the Hands of - - PowerPoint PPT Presentation

Mar 03, 2024 317 likes •720 views

The Roadmap to Machinery Safety Putting Performance in the Hands of Your People Agenda Drivers of Machine Safety Projects Overview of OSHA and Standards Roadmap to Machinery Safety Drivers of Machine Safety Programs Incident Reaction

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SLIDE 1

Putting Performance in the Hands of Your People

The Roadmap to Machinery Safety

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SLIDE 2
  • Drivers of Machine Safety Projects
  • Overview of OSHA and Standards
  • Roadmap to Machinery Safety

Agenda

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SLIDE 3

Drivers of Machine Safety Programs

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SLIDE 4

Incident Reaction

  • Improper Installation of Safety

Devices

  • Inappropriate usage of safety

Device

  • Improper installation of hard

guarding

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SLIDE 5

Incident Reaction

  • Improper Installation of Safety

Devices

  • Inappropriate usage of safety

Device

  • Improper installation of hard

guarding

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SLIDE 6

Drivers of Machine Safety Programs

We are committed to providing a safe and healthy workplace for our employees … We will provide the leadership necessary to create a culture in which all employees accept personal responsibility for workplace safety & health.

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SLIDE 7

Culture of Safety

  • Safety Committee
  • Employee “Buy-In”
  • Recognize the safety issues
  • Implement practices and procedures
  • Employee Empowerment
  • Safety Training
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SLIDE 8

Culture of Safety

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SLIDE 9

Drivers of Machine Safety Programs

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SLIDE 10
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SLIDE 11

OSHA Top 10 Violations for 2014

Standard Total Violations

1

Fall Protection (1926.501 6,348

2

Scaffolding (1926.451) 4,533

3

Hazard Communication (1910.1200) 3,282

4

Ladders (1926.1053) 2,688

5

Lockout/Tagout (1910.147) 2,447

6

Machine Guarding (1910.212) 2,204

7

Powered Industrial Trucks (1910.178) 2,198

8

Electrical-Wiring Methods (1910.305 2,191

9

Respiratory Protection (1910.134) 2,154

10 Electrical-General Req. (1910.303)

1,715

(Data as of Nov. 3, 2014)

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SLIDE 12

Overview of Standards

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SLIDE 13

US Standards

  • 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

  • ANSI – Coordinates Voluntary

Standards

  • ANSI – Official representative to

ISO/IEC

  • TUV – OSHA recognized NRTL
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SLIDE 14

OSHA Standards on LOTO

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)

1910.147(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

  • perations 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.

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SLIDE 15

European Standards

  • Goal to achieve free movement of

goods and protecting its citizens

  • EU-Directives define:
  • Basic product Requirements
  • Basic requirements for safe
  • peration
  • Minimum requirements for safety

at work

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

Machinery Directive 2006/42/EC Work Equipment 2009/104/EC

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SLIDE 16

Global Machine Safety Standard Convergence

Global Convergence

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SLIDE 17

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

  • r a particular group of machines

Source: Rockwell Automation

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SLIDE 18

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

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SLIDE 19

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

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SLIDE 20

Roadmap to Machine Safety

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SLIDE 21

Proven Roadmap to Machine Safety

Risk Assessment Define Design

Implement

Validate

Technology Transfer & Training REGULATORY AND SAFETY STANDARDS

SAFE MACHINE STATE

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SLIDE 22

Proven Roadmap to Machine Safety

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SLIDE 23

Risk Assessment

Risk Assessment

Define Design Implement Validate

  • Importance of performing a Risk Assessment
  • Risk Assessment is referenced throughout US safety standards
  • ANSI Z244.1
  • ANSI B11.19
  • ANSI/RIA R15.06
  • NFPA 79
  • Note that ANSI/RIA 15.06 requires a risk assessment starting January

2015.

  • Risk Assessment in the EU is a requirement to obtaining a CE label
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SLIDE 24

Risk Assessment

ISO 12100

Risk Assessment

Define Design Implement Validate

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SLIDE 25

Risk Assessment Identification of Hazards

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SLIDE 26

Risk Assessment Risk Estimation

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SLIDE 27

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

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SLIDE 28
  • 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

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SLIDE 29

Risk Assessment

Risk Assessment

Define Design Implement Validate

  • RISK Assessment Exercise
  • WHO – is involved
  • WHAT – is the machine’s function
  • HOW – can someone get injured
  • WHAT – Type of injury can occur
  • What – is the risk of the injury
  • HOW – to protect against the injury
  • IS – the risk reduction acceptable for the hazard
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SLIDE 30

Definition

  • Definition
  • High level Design
  • Project Plan

Risk Assessment

Define Design Implement Validate

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SLIDE 31

Definition

  • Definition
  • Tools

Risk Assessment

Define Design Implement Validate

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SLIDE 32
  • Design/Engineering
  • Safety Functional Design Specification (SFDS)
  • Safety Design
  • Hardware/Software Bill of Materials
  • Installation bids (Electrical/Mechanical)
  • Final Scope, Schedule, and Cost
  • Documentation

Design

Risk Assessment

Define Design Implement Validate

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SLIDE 33

n j j j

Design

ISO 13849-1

Risk Assessment

Define Design Implement Validate

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SLIDE 34
  • Implementation
  • Safety Control Panel Fabrication
  • Programming (PLC / HMI)
  • Hardware / Software Procurement
  • Installation and Verification
  • Proper installation is key to the reliability of the entire

system

  • Documentation

Implement

Risk Assessment

Define Design Implement Validate

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SLIDE 35

Implement

Risk Assessment

Define Design Implement Validate

BEFORE AFTER

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SLIDE 36
  • Validation of safety system
  • Manage Validation Process
  • Safety Circuit / Function Validation
  • Normal / Abnormal conditions
  • Documentation

Validate

Risk Assessment

Define Design Implement Validate

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SLIDE 37

Validate

ISO 13849-2

Risk Assessment

Define Design Implement Validate

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SLIDE 38

Proven Roadmap to Machine Safety

  • Technology Transfer & Training
  • Training Needs Analysis
  • Training Documentation Development
  • Training Facilitation
  • Training Validation
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SLIDE 39

Questions

39