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Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 1
RAOTM 2018 – T77 – Improving Productivity using
Contemporary Safety Designs
Rajendran A Menon
Product Manager – Safety, Sensing & Connectivity Business
FS Eng (TUV Rheinland , #4597/11, Machinery)
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Agenda
Application Example – System Optimization of Tc
Application Examples – Configurable Designs
Emerging Design Philosophies
Functional Safety Life Cycle
Safety as a Core System Function
Advanced Safety Concepts
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t © 2010
Safety as a Core System Function
Safety continues to emerge as core system function
Value – Safety as a Key Differentiator:
Global Compliance
Common Designs
Reduced Costs
Increased Productivity –
Systematic MTTR Reduction
Improved Competitiveness
Reduced Floor Space and Direct Labor
Improved Ergonomics
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Safety as a Core System Function…But How?
New Tools:
Emergence of Global Specifications – ISO, IEC Standard Machine Designs that are Globally Compliant
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”
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Functional Safety Life Cycle
STEP 5MAINTAIN & IMPROVE
SAFETY SYSTEM
STEP 1RISK OR HAZARD
ASSESSMENT
STEP 4SAFETY SYSTEM INSTALLATION &
VALIDATION STEP 3SAFETY SYSTEM
DESIGN & VERIFICATION
STEP 2SAFETY SYSTEM
FUNCTIONALREQUIREMENTS
Functional SafetyLife Cycle
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Risk Assessment – The Foundation
Provides Safety Performance Level – Design Target
Creates the Foundation of the Safety System Functional Requirements, System Design and Validation Protocol.
Shows “Due Diligence” and Global Compliance (Ref. ISO 12100)
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
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Emerging Design Philosophies
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/downtime
Safety AND Productivity
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Improved Productivity by Design: MTTR Reduction
RunningDown
Ma
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
Ma
ch
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
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Safety Application - Perimeter Guarding
Gate Entry Box
• OFF (AUTO)
• Tool Outputs ON, Transfer Motion OFF
• Tool Outputs ON, Transfer Motion ON
• OFF (AUTO)
• Outputs ON, Servos OFF
• Outputs ON, Servos ON
Robots
Tooling
Easy, Intuitive and Secure
Point of Entry Configurable Safety System
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Safety Application - Perimeter Guarding
Results:
No need to bypass the safety system - It is designed to safely
accommodate the maintenance and operating procedures.
Higher productivity - Safety system may be used in lieu of
LOTO ( Lockout/Tagout) for many routine maintenance and
setup procedures.
Improved MTTR, faster start-ups, highly standardized
approach System is PASSIVE – The Easy Way is the Safe Way.
System is Lockable
Reduction of injuries and associated costs.Engineered and Integrated Safety Systems
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Improved Productivity: Safety System Design
If the safety system design meets target
safety level, and ANSI Z244-1 applies…
The safety system may be used in lieu
of LOTO, reducing MTTR by ~2
minutes.
Manufacturer’s value of 1 minute
of production = $10K
Average downtime events
per plant per year = 3000 (8/day)Safety = Productivity = Profitability
$10K X 2min X 3000 =
$60M/yr.
Value of safety solution due to improved
productivity (reduced MTTR)
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Safety System Optimization – What? Why? How?
What? - Safety System Optimization
Reduction of Safety Control System Latencies.
Simplification and Standardization of Safety Functions
Why? - Provides Manufacturing Systems that:
Reduce Staffing Requirements, Reduction in Direct Labor via Improved Labor
Efficiencies
Reduction of System Floorspace/Footprint
Reduction of Machine Cycle Times, Improved Productivity
Improved Ergonomics and Reduced Operator Strain
Ok – sounds good but….HOW???
Optimized Safety Systems can Reduce Costs!
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Safety System Optimization – Safe Distance
Optimization of Tc
Safe Distance Calculation is Ds = K(Tr + Ts + Tc) + Dpf
Systematic Reduction of safety control system latencies
Method 1 - Local processing – Safety “Chicken Brains”
Method 2 - Network scheduling RPI and safety task interval
Method 3 – Combination with Hardwired Systems
Improves: Operator Utilization, Floorspace utilization, Ergonomics
Goal is to Architect Faster System Response
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Safety System Optimization – Safe Distance
Table 6 from ANSI/RIA 15.06
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t © 2009
Safety System Optimization - Example
Valve
bank
Tool or
FixtureOperator
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t © 2009
Safety System Optimization - Example
Valve
bank
Tool or
FixtureOperator
Motion Causing
Output Power
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t © 2009
Safety System Optimization - Example
Valve
bank
Tool or
FixtureOperator
Motion Causing
Output Power
SIO SIO SIO
GLx
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t © 2009
Safety System Optimization - Example
Valve
bank
Tool or
FixtureOperator
Motion Causing
Output Power
Tc = RPI + GLx Scan + RPI
= 50ms + 20ms + 50ms
= 120ms
.
.
.
SIO SIO SIO
GLx
Ref: Ds = K(Tr + Ts + Tc) + Dpf
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t © 2009
Safety System Optimization - Example
Valve
bank
Tool or
FixtureOperator
Motion Causing
Output Power
SG600 SIO
GuardLogix
Tc = SG600 Scan
= 20ms (or less!)
Over 6” Ds Reduced!
Ref: Ds = K(Tr + Ts + Tc) + Dpf
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Solution Value
Reduced System Floorspace
6” reduction X 4’ load window width = 2 sq ft per load window reduced
2 sq ft X 150 load windown/shop = 300 sq ft/shop reduced floorspace
300 sq ft X $100/sq ft/yr = $30K/yr savings (not incredible…)
Improved Operator Utilization
Typical Operator Cycle Break LC and move to load point 1.5 sec
Load Parts 5.0 sec
Exit load window 1.5 sec
Palm/Initiate Cycle 1.0 sec
Total = 9.0 sec
Our 6” Ds savings may reduce this operator cycle by 0.5 sec overall; 0.5/9=5.6%
If designed in, this may reduce direct labor by 5 headcount (100 person shop reduced 5%)
5 direct labor X $100K/head/yr (burdened) = $500K/yr reduced labor costs
Improved Ergonomics?Cost Savings can be Significant
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Safety System Optimization – Other Approaches
How else could Tc be improved?
RPI’s configured to the application requirements
Hardwired approach
How could Ds be improved?
Ref: Ds = K(Tr + Ts + Tc) + Dpf
Can we affect Tr or Ts?
What about Dpf?
Safety System Optimization Requires a Systematic Approach
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Safety System Optimization – New Thinking
Safe Motor Control – Controlling the Hazard
Typically either “On” or “Off” today – Contactors.
Safe Off, Safe Speed available today – Safe direction, position coming.
For Maintenance personnel, Operators
Changing the way hazards are managed Modulating hazards based upon human proximity vs shutdown.
Human Detection Methodology
Old Way – Simple “Go” or “No Go”
New Way – Multiple stage Detection with “Layers”
New Safety Technologies will Change the way Hazards are Managed
MSR-57
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Safety System Optimization – New Thinking
Safe Motor Control – Safe Speed
Modulate Hazard rather than shut down
What does this do for Safe Distance
Calculation Ds? Ds = K(Tr + Ts + Tc) + Dpf
Decreased cell size, Improved Uptime,
reduced ergonomic load
Safe Zero Speed or “Standstill” for Operator Load
Energy Conservation
Load Work
MSR-57
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Competitive and Safe Machines
Provides improved Machine Uptime & Ergonomics
Modulates Hazard rather than shutting down
Reduces Walk Distances
Can help remove incentive to bypass the Safety System
System is operator and maintenance friendly
New Safety Technologies enable these advanced
Safety Functions
Improved Safety AND Improved Productivity!
Load Work
MSR-57
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Questions?