Machine Safety Protecting your Most Valuable Assets Putting Performance in the Hands of Your People
Agenda • Safety – Protecting Your Assets • Roadmap to Machine Safety • Global CPG Case Study
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.
Are your Employees Safe? • Culture of Safety • Employee “Buy - In” • Recognize the safety issues • Implement practices and procedures • Employee Empowerment • Safety Training
Safety and Productivity 39% OEE: 5% - 7% 26% Unscheduled 23% 18% Downtime: 2% - 4% Invest in Safety Technology Establish Corporate Safety Program Best in Class All Others
What is Machine Safety? Machine Safety: Refers to safeguards that are applied to both machinery and the operators 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 REGULATORY AND SAFETY STANDARDS Hazard Audit SAFE Design Validate Implement Define MACHINE STATE Risk Assessment Technology Transfer & Training
Proven Roadmap to Machine Safety – Risk Assessment • Hazard Audit ISO 12100 • Risk Assessment • Determine Limits • Identify Hazards • Estimate the Risk • Evaluate the Risk • Reduce the Risk • Document the process
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 Protective Measures Examples • Design It Out Eliminate the Risk • Process Substitution Most Effective • Fencing or Barriers Physical Guarding • Fixed Covers • Interlocks, Light Curtains, Safety Mats Engineering Controls • Monitoring Relays, Safety PLCs (Safeguarding Technology) • Signs, Warnings, Annunciation Lights Awareness Means • Safety Glasses, Gloves & Footwear (Personal Protective Equipment) Least • Work Procedures Training & Procedures Effective • Lockout / Tagout (LOTO) (Administrative Controls)
Addressing Residual Risk • 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.”
Proven Roadmap to Machine Safety – Definition • Definition High level Design Project Plan
Proven Roadmap to Machine Safety – Design/Engineering • Design/Engineering Safety Functional Design Specification (SFDS) Safety Design Hardware/Software Bill of Materials Installation bids (Electrical/Mechanical) Final Scope, Schedule, and Cost ISO 13849-1
Proven Roadmap to Machine Safety – Implementation • 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 – Validation • Validation of safety system Manage Validation Process Safety Circuit/Function 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
Global CPG Manufacturer Case Study • 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.
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
Successful Upgrade 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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