Ensuring Machinery Safety, Compliance, and Productivity. · Ensuring Machinery Safety, Compliance,...

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

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Ensuring Machinery Safety, Compliance, and Productivity.

PackExpo - September 2015

George Schuster

Global Safety BusinessSteve Ludwig

Program Manager, Safety

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Agenda

Summary

Is This Machine Safe?

Design Philosophies for Systematic MTTR Reduction

Functional Safety Lifecycle

The Safety Landscape, Tools for Functional Safety

Challenging Perceptions

Risk, Value, and Safety Maturity

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 3


Bill Hilton, Director of Health and Safety

“A historical lack of accidents does not imply a

current presence of safety. It simply means

you’ve been faster than the machine.”



4

“I will say that I cannot imagine any condition which could cause a ship to founder. I cannot conceive of any vital disaster happening to this vessel. Modern shipbuilding has gone beyond that.”

- Captain EJ SmithCaptain, HMS Titanic

“What a strange sense of logic to fixate on the absence of something (injury) as a demonstration of the presence of something else (safety). Such a proposition misunderstands the dynamic of risk and being human.”

“Measuring safety by the number of injuries is like measuring parenting by the number of smacks you give.”

– Dr. Robert Long, 2014 Human Dymensions


Risk vs Safety

5


What if?

• Reduce Injury Rate by Half

• Increase Overall Equipment Effectiveness (OEE) 5%-7%

• Reduce Unscheduled Downtime 2%-4%

Best-In-Class Performance


Business Risks

7

• Aging Workforce• Retiring workers

• Loss of skills and knowledge

• Unfilled jobs

• Inexperienced workers at higher risk

• 40% reduction in productivity growth

• Supply Chain Interruption Causes• Accidents #1

• Production #2

• Labor availability #3

• Financial loss and premiums #6

• Regulatory #8

• Lawsuits #10

• Reputational / Brand Risk• Worker treatment / injuries

• Environmental

• Labor


• 5%-7% Higher OEE

• 2%-4% Less Downtime

• <50% injury rate

Business Value


Safety Maturity

Culture (behavior): The company DNA from upper

management support, cross-functional safety teams,

observable.

Compliance (procedure): Established risk

management processes, procedures, and standards

to identify, prioritize and mitigate risks

Capital (technology): Investments in technologies

that improve both safety and productivity.

Contemporary safety solutions and technologies are

seen as a viable investment with an ROI.

Safety Safety Life CycleLife Cycle

5. Maintain & Improve1. Hazard or Risk

Assessment

4. Installation & Validation

2. Functional Requirements

3. Design & Verification

Safety Safety Life CycleLife Cycle

5. Maintain & Improve1. Hazard or Risk

Assessment


2. Functional Requirements


What differentiated Best-in-class Manufacturers from their Peers?

http://www.amazon.com/gp/product/images/0977830802/ref=dp_image_0?ie=UTF8&n=283155&s=books

http://www.amazon.com/gp/product/images/0977830802/ref=dp_image_0?ie=UTF8&n=283155&s=books


Good Companies: Safety = Cost Savings/Avoidance

Great Companies: Safety = Performance


Source – Rockwell Automation, 2013 Manufacturing Safety Effectiveness Study

by The Aberdeen Group

15%

23%

37%

25%

Level

SMI4 SMI3 SMI2 SMI1


New Safety Landscape


New Safety Landscape

• Design-In Safety - a Core System Function

• Safety as a Core Machine Value: Global Compliance

Common Designs

Reduced Costs

Increased Efficiency –

Systematic MTTR Reduction

Improved Competitiveness

Reduced Floor Space; Reduced Labor

Improved Ergonomics; Reduced Injuries


Functional Safety – Do we have a Problem?

• Are Safety Procedures Ever Bypassed?– Do People take the “Short Cut” to expedite

maintenance procedures?

– Is LOTO (Lock Out Tag Out) always followed?

Safety must be Easy and Intuitive

• Are Safety Systems or Technologies ever

Bypassed?– Are people using a “Cheater Key”?

– Some systems are so poorly designed and

integrated that maintenance people are forced to

bypass the safety system just to get their jobs done!


Tools for Functional Safety

Emergence of Global Specifications

Standard Machine Designs that are Globally Compliant

ISO 13849; IEC 62061

New Safety Technologies – Tools for Improved

Machine Performance

New Design approaches – Passive, Configurable and Lockable

“Design-In” Safety for user-friendly machines

A Systematic Design Approach is Required.

These systems don’t just happen!

The Rigor of The Functional Safety Lifecycle

Safety By Design

Safety is a “Way of Life”


Functional Safety Life Cycle

Functional Safety Life Cycle

ISO 13849

5. Maintain & Improve

1. RiskAssessment


2. Functional Requirements Specifiation



Risk Assessment – The Foundation

• A “Task-Based” , Team Approach – Builds Consensus, Repeatable

• Provides Safety Performance Level – Design Target

• Creates the Foundation of the Safety System Functional Requirements, System Design and

Validation Protocols.

• Shows “Due Diligence” and Global Compliance (Ref. ISO 12100, 14121)

S1

S2

F2

F1

Performance

Level, PLr

a

b

P1

P2

e

c

d

P1

P2

P1

P2

P1

P2

F2

F1

S = SeverityF = Frequency or Duration of ExposureP = Avoidance Probability

Task/Hazard

Contribution

to Risk

Reduction

Low

High

Steps Include: Identification of Cross- Functional Team

Determination of Machinery Limits &

Functions

Identification of Tasks & Associated

Hazards

Risk Estimation & Evaluation

Risk Reduction and Mitigation

Documentation


Design Philosophies – Systematic MTTR Reduction

• Passive System Design Ensures the easy way is the safe way

• Configurable System Design Ensures the necessary functionality to

accommodate complex and variable maintenance procedures – by design.

Helps to limit exposure to hazards while removing the need or incentive to bypass.

• Lockable Safety Systems ANSI Z244-1 Compliant Systems that systematically reduce MTTR and

improve Efficiency.

Safety AND Productivity


Improved Productivity by Design:Systematic MTTR Reduction

RunningDown

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ch

ine

Sto

ps

Ma

inte

na

nce

Arr

ive

s

Fa

ult Id

en

tifie

d

LO

TO

Re

pa

ir P

erf

orm

ed

Mach

ine U

nlo

cked

Re

pa

ir T

este

d

Ma

ch

ine

ba

ck in

Au

to

Pro

du

ctio

n R

esu

me

s

MTTR = 12 minutes (avg.)

Running

Typical Downtime Event



Was a Risk Assessment Performed

Cross-functional Team-based?

All Task/Hazard Pairs Evaluated?

All Operating Modes Considered?

Target Risk Reduction Levels Identified?

Mitigations Evaluated and Outlined?

Residual Risk Recorded?

Documentation Completed?

Risk Assessment is the Foundation



Was a Safety Functional Requirements Specification (SFRS) Created?

Detailing Span of Control for all Safety Functions (SF’s)?

All Operating Modes Considered?

Behavior under Faults and Failures Documented?

All Use Cases Mapped?

SFRS Defines the Safety System Requirements



Has the Engineering Design been Verified?

Verification plan Generated?

All SF’s Reliability Modeled?

All Safety Component Data Recorded?

SF’s modeled for Structure (Cat.), Reliability (MTTFd), Diagnostic

Coverage (DC) and Common Cause Failures (CCF)?

Results Compared to PLr requirements from the Risk Assessment?

Results Documented, Report Generated?

Reference SISTEMA for ISO 13849

http://www.dguv.de/ifa/Praxishilfen/Software/SISTEMA

Verification Helps Ensure No Design nor Specification Errors



Has the Build and Installation been Validated?

Validation Plan Created? Escalation Plan?

Includes Functional and Fault Injection Tests?

Includes all Modes of Operation?

Tests all Field Devices?

Results Documented, Report Generated?

Validation helps ensures no Errors during Build/Installation


Summary

Safety Maturity Index

Achieving Operational Excellence

New Tools for Functional Safety

The Functional Safety Lifecycle is your guide

New Design Philosophies – Systematic Reduction of MTTR

Is this Machine Safe? Things to check!

Risk Assessment?

Design Verified?

System Validated?

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