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 Improper Installation of Safety Devices Inappropriate usage of safety Device Improper installation of hard guarding
Incident Reaction Improper Installation of Safety Devices Inappropriate usage of safety Device Improper installation of hard guarding
Drivers of Machine Safety Programs We will provide the leadership necessary to create a culture in which all employees We are committed to accept personal responsibility for providing a safe and healthy workplace safety & health. workplace for our employees …
Culture of Safety • Safety Committee • Employee “Buy - In” • Recognize the safety issues • Implement practices and procedures • Employee Empowerment • Safety Training
Culture of Safety
Drivers of Machine Safety Programs
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)
Overview of Standards
US Standards • OSHA - The law “ have to comply” • States must meet or exceed • OSHA Regulations defined in C ode of F ederal R egulations Title 29 • Reference to Standards such as ANSI and NFPA • ANSI – Coordinates Voluntary Standards • ANSI – Official representative to ISO/IEC • TUV – OSHA recognized NRTL
OSHA Standards on LOTO Part 1910: Occupational Safety and Health Standards Subpart O: Machinery and Machine Guarding 1910.147(a)(2)(ii) The minor servicing exception 1910.211: Definitions provides that minor tool changes and adjustments and other minor servicing activities which take 1910.212: General Requirements for place during normal production all Machinery operations may be exempt from the LOTO standard if the activity is 1910.213-190.219: Machine Specific routine, repetitive, and integral to Regulations the use of the equipment for production purposes, provided that the work is performed using Subpart J: General Environment Controls alternative measures which provide effective employee 1910.147: The Control of Hazardous protection. Energy (Lockout/Tagout)
European Standards • Goal to achieve free movement of goods and protecting its citizens • EU-Directives define: • Basic product Requirements • Basic requirements for safe Machinery Work operation Directive Equipment • Minimum requirements for safety 2006/42/EC 2009/104/EC at work • Technology neutral • Standards Not Mandatory – is a legal obligation to keep to the EU-Directives • “Declaration of Conformity”
Global Convergence Global Machine Safety Standard Convergence
Three-tier Safety Standards Structure EXAMPLES: 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 Fundamental safety standards applicable to all Equipment Type A machine. Type A standards deal with basic concepts, principles for design, and general ANSI/NFPA 79 – Electrical standard for Industrial aspects. Machinery Standard applicable to a wide range of machinery. Type C Type B is divided into two categories: EN 12012 – Safety requirements - Plastics and Rubber Type B B1: Specific safety aspects (i.e., safety distance, machines surface temperature, and noise.) B2: Safety related devices (i.e., two-hand controls, ISO 10218 - Safety requirements – Industrial Robots interlocking devices, pressure sensitive devices and guards) ANSI/B155.1 - Safety Requirements for Packaging Machinery and packaging-Related Converting Type C Detailed standards applicable to a specific machine Machinery 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
Roadmap to Machine Safety
Proven Roadmap to Machine Safety REGULATORY AND SAFETY STANDARDS SAFE Risk Design Validate Implement Define MACHINE Assessment STATE Technology Transfer & Training
Proven Roadmap to Machine Safety
Risk Assessment Risk Define Design Implement Validate Assessment • 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
Risk Assessment Risk Define Design Implement Validate Assessment ISO 12100
Risk Assessment Identification of Hazards
Risk Assessment Risk Estimation
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.”
Risk Assessment Risk Define Design Implement Validate Assessment • 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
Definition Risk Define Design Implement Validate Assessment • Definition High level Design Project Plan
Definition Risk Define Design Implement Validate Assessment • Definition Tools
Design Risk Define Design Implement Validate Assessment • 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 Define Design Implement Validate Assessment ISO 13849-1 n j j j
Implement Risk Define Design Implement Validate Assessment • 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 Define Design Implement Validate Assessment AFTER BEFORE
Validate Risk Define Design Implement Validate Assessment • Validation of safety system Manage Validation Process Safety Circuit / Function Validation Normal / Abnormal conditions Documentation
Validate Risk Define Design Implement Validate Assessment ISO 13849-2
Proven Roadmap to Machine Safety • Technology Transfer & Training Training Needs Analysis Training Documentation Development Training Facilitation Training Validation
Questions 39
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