Smart Safetyn Increase productivity

n Minimise downtime with diagnostic information from the safety system

n Benefit from the broadest portfolio of safety products, solutions and services

n Enable smarter machines for use in The Connected Enterprise

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Smart Safety – enabling smarter machines and equipment

Challenges to safe operations

Evolving workforce ¡ Safety implications of major workforce shift worldwide

¡ Older workers nearing retirement at higher risk for musculoskeletal injuries

¡ Younger, less experienced workers more prone to injury

Worker behaviours ¡ Operators bypassing poorly designed safety systems

¡ Systems that don’t account for procedural anomalies

¡ Standard operating procedures not being followed

Regulatory compliance ¡ Compliance with industry standards can be challenging

¡ Documenting and reporting on approved safety systems can be challenging

Machinery downtime ¡ Downtime for jams, misfeeds, adjustments, changeovers and maintenance

¡ Minimal visibility of downtime information

¡ No context of downtime issues (workers interaction, machinery fault, shift patterns)

¡ Limited information to remedy issues

Data management ¡ Continuing reliance on outdated data collection and reporting methods

¡ Safety data often manually entered for inspections, compliance logs, incident reports, training and other processes

¡ Systems in which data is stored typically not connected to plant floor systems

Harnessing the power of safety and operational data can substantially improve safety compliance and performance. Accessing safety system data and transforming it into meaningful information results in increased machinery productivity, and minimises downtime.

To gain more diagnostic data traditional safety devices required more complex wiring solutions. With a Smart Safety solution, you can now access more diagnostic data and simplify your wiring system.

An integrated Smart Safety solution provides all the data needed to create a comprehensive picture of the status of the machine or production line.

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Access to real-time data and seamless connectivity is transforming the production environment. Smart capabilities enable end users to gain new efficiencies, improve product quality and make operations more responsive. Smart Safety helps to standardise machinery and safety control. These systems are less susceptible to nuisance shutdowns and can help to improve productivity and profitability.

SAFE SPEED ACTIVATION OBJECT DETECTED.

Average times per hour

0 0 0 2DAMAGED SWITCH

! ! ! !

Damaged Switch! Zone 1, Conveyor

!

LOW MARGIN Per week

0 0 0 2

Low Margin! Cleaning required

!

Misalignment! Line 1, guard door 3

!

Number of operations monitored for replacement scheduling.

Why is the E-stop function being operated so much?

0 0 1 0! LIGHT CURTAIN

Times tripped per day

0 0 2 0! EMERGENCY STOPS

Times tripped per day

0 0 0 9

PALLETIZER ACCESS Requests in 24hrs

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Smart Safety devicesSmart Safety solutions provide detailed diagnostic data to your design environment, visualisation system, information software, and GuardLogix Programmable Automation Controller – enabling Smart Machines for use in The Connected Enterprise and helping to increase productivity and minimise downtime while reducing total cost of ownership.

The Connected Enterprise/Industry 4.0

EtherNet/IP EtherNet/IP

Input

Emergency stop

Non contact switches

Guard locking switches

Safety over GuardLink (up to PLe SIL3)

Safety over EtherNet/IP (up to PLe SIL3)

Key Interlock Switches

Cable pull switches

Multifunctional Access Box

Light Curtains

Safety Scanner

Logic Output

VisualisationDesign

EnvironmentLogix Programmable

Automation Controller Benefits of Smart Safety

Information Software

Cable reduction of up to 38%

I N T E G R A T E D S A F E T Y S O L U T I O N S

APPLICATIONKNOWLEDGE HMI

INDUSTRYSOLUTIONS

I N T E G R A T E D S A F E T Y S O L U T I O N S

SOFTWARE

SAFETY INPUTSSAFETY LOGICCONTROLLERS

CONNECTION SYSTEMS

LEGISLATION& STANDARDS

GUIDANCE

DESIGNTOOLS

SAFETYSERVICES

SAFETY OUTPUTS

CONNECTION SYSTEMSCONNECTION SYSTEMS

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Smart Safety enables Smart Machines for use in The Connected Enterprise

A solution incorporating Smart Safety devices enables safety professionals to transform the way they monitor and manage safety. Rockwell Automation provides a complete Smart Safety solution to meet safety requirements, covering safety input devices, safety logic and safety output devices.

Improve insight into worker behaviour and complianceBy incorporating safety information into EHS management systems, day to day discrepancies between policies and operating procedures can be identified

Enhance safetyConnecting people, equipment and worksites creates new opportunities to enhance worker and environmental safety, including remote access, operations visibility, worker locating and information delivery via mobile devices.

Reduce safety-related downtimeBetter visibility into safety-system performance and stoppages can help determine the root cause of shutdowns. Safety and production data also can be combined to understand the frequency, duration, time and location of safety-related shutdowns.

Improve complianceThe safety data required for compliance and reporting purposes is largely collected through time-consuming, error-prone manual audits today. By integrating auditing functions into the HMI and controller, organisations can automate and speed up the auditing process, free up personnel to focus on other priorities, and reduce the likelihood of errors.

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Visit www.machinesafetysolutions.com to see how Smart Safety can make the difference

Remote troubleshooting with Smart Safety

¡ Safety device performance communicated over EtherNet/IP

¡ Predictive maintenance routines established from historical data

¡ EtherNet/IP network allows standard and safety data to be captured on individual device operation

¡ Simplifies wiring and system complexity ¡ All time stamped data of device operation available in FactoryTalk Historian

5. All device interactions are captured in system. Data can be used for predictive maintenance plans.

3. Machine operator cleans the light curtain, preventing unnecessary machine downtime.

1. Light curtain has buildup of dirt reducing sensing field. 2. Machine operator quickly informed which light curtain has an issue.

4. All smart devices on the machine give current status information to operator, where and when it is needed.

6. Machine working efficiently and with predictive maintenance planned.

Scenario 1

65

1 2

3 4

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Visit www.machinesafetysolutions.com to see how Smart Safety can make the difference

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3 4

Request safe access over EtherNet/IP network

¡ Guard position, lock status and access request managed over standard unmodified ethernet (Safety over EtherNet/IP)

¡ Historical data of access request can be used for application adjustments

¡ Simplified network architecture for standard and safety control

¡ Add-on profile in Studio 5000 provides simplified setup and monitoring

¡ Indication given separately for guard door position and guard lock status

5. Machine operator closes guard door, initiates a reset request which locks the guard closed. Request logged in system.

3. System checks for safe condition and then grants access. Access approval logged in system.

1. Box falls from pallet in shrink wrapper due to speed of conveyor.

2. Machine operator requests safe access via smart safety interlock device. Request action logged in system.

4. Machine operator safely enters machine and replaces fallen box.

6. All data logged in system is available to enable machine performance adjustments.

Scenario 2

3

Visit www.machinesafetysolutions.com to see how Smart Safety can make the difference

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Machine uptime from Smart Safety data

¡ Access frequency into the machine through individually identified access points, is available with Smart Safety

¡ Smart Safety allows data to be captured on individual device operation

¡ Simplifies wiring and system complexity ¡ Smart Safety can be used with your existing safety devices

¡ Historical data of access request can be used for application adjustments

Scenario 3

5. Production manager and machine operator discuss reason of frequent access. Tape causing problem can be replaced.

3. Machine operator restarts machine.

1. Tape from supplier frequently breaking. 2. Machine operator opens interlocked guard door to fix tape. Device operation is logged in system.

4. Production manager has all data available on safety device actions.

6. Machine running more efficiently with less maintenance required.

65

1 2

3 4

Visit www.machinesafetysolutions.com to see how Smart Safety can make the difference

Smart Safety 9

65

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Predictive maintenance with Smart Safety solution

¡ Smart Safety allows predictive maintenance procedures to be adopted based on device use or age

¡ Smart Safety allows data to be captured on individual device operation

¡ Simplifies wiring and system complexity ¡ Smart Safety can be used with your existing safety devices ¡ Historical data of access request can be used for application adjustments

5. Device can be replaced at next planned maintenance schedule.

3. Monitoring number of operations helps predict when device is at end of life.

1. Operations of safety devices per shift are captured. 2. All safety device operational use from manufacturing line available.

4. Information is available for maintenance staff to replace device.

6. Machine downtime reduced to a minimum.

Scenario 4

3 pillars of support for your safety requirements

The right productsRockwell Automation has the broadest portfolio of any machinery safety solutions supplier, and can provide all three parts of a safety system.

Safety input devices• Presence-sensing safety devices• Safety interlock switches• Emergency stop & trip devices• Operator interface

Safety logic controllers• Safety relays• Configurable safety relay• Integrated safety controllers• Safety I/O devices

Safety actuators• Safety contactors• PowerFlex® AC drives• Kinetix® integrated motion

Connection systems/networks• ‘Quick connect’ connection systems• Safety over EtherNet/IP• GuardLink linking technology

The right toolsA wide range of tools that support compliance with safety standards, reduce the risk of injuries and improve productivity.

Safety Automation BuilderFREE software tool to help simplify machine safety design and validation, reducing time and costs. Integration with RASWin Risk Assessment Software provides you with consistent, reliable, documented management of the Functional Safety Lifecycle.

SISTEMA integrationThe SISTEMA tool automates calculation of the attained Performance Level outlined in (EN) ISO 13849-1. Data is available to be used with the SISTEMA calculation tool.• Helps users in the design stage• Comprehensive Rockwell Automation database

Pre-engineered Safety FunctionsMachine safety can be developed by combining blocks of safety functions. Our pre-engineered safety functions come with a SISTEMA Performance Level calculation as outlined in (EN) ISO 13849-1.• Reduces design times• Includes set-up, wiring, configuration and validation information• Complete bill of materials

Accelerator ToolkitsEasy to use system design, programming, and diagnostic tools to assist in the rapid development and deployment of safety systems.• Reduces design time and risk

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The right peopleA comprehensive range of safety services and support is available from both Rockwell Automation and its machinery safety certified ‘Recognised System Integrator’ partners.

TÜV Rheinland certified machine safety training coursesHelping deliver staff training that qualifies towards an industry-standard TÜV Rheinland Certificate, enabling trainees to understand safety requirements and compliance.

Risk Assessment ServiceRockwell Automation’s global safety team of consultants and partners can assist end users, integrators and OEMs at any step of a safeguarding project. Comply with safety standards to reduce the risk of injuries and improve productivity.

Trained staff and partnersRockwell Automation has TÜV Rheinland machinery safety qualifications it requires its employees and partners to achieve in order to support you. Leverage their knowledge now.

Knowledge of automation and safetyThe benefit of partnering with Rockwell Automation is you gain the support and expertise of people who understand automation and safety, not just safety.

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Allen-Bradley, LISTEN. THINK. SOLVE., Rockwell Software, Studio 5000 and Studio 5000 Logix Designer are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

Rockwell Automation, Inc. (NYSE:ROK), the world’s largest company dedicated to industrial automation, makes its customers more productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley® and Rockwell Software® product brands are recognised for innovation and excellence.

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Publication SAFETY-BR002A-EN-P July 2017 Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved.