the voice of operational excellence cost savings … voice of operational excellence cost savings of...

The Voice of Operational Excellence

COST SAVINGS OF INTEGRATING SAFETY: A CASE STUDY

Presented By Jeff Winter, ASP, FS. Eng.

September, 2015

Achieving Operational Excellence through combining safety and automation projects

Trends in Machine Safety

Capital Project Savings Considerations

Engineering Savings Considerations

Operational Savings Considerations

Cost Savings of Integrating Safety

2 | The Voice of Operational Excellence

History of Machine Safeguarding Technology

Prevent Access Detect Access Control Access

Major changes in

machine technology

and standards

3 | The Voice of Operational Excellence in Automation

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Integrating Safety and Automation Technology

Physically Independent


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Separate Automation Control

Architecture

Separate Safety Control

Architecture

Integrated Safety and Automation

Control Architecture


Safety Functions are becoming more Complex

Simple Detection Single Function Safety Control Power Shut-Off

Configurable Detection

Programmable Safety Control Safe Motion ControlControlled Access


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Why is this so important right now?

Safety Standards

Safety Technology




THE PROBLEM:

Separation of safety and engineering projects can add incremental cost to an annual capital expense budget

Case Study 1: Combining Projects


TWO PROJECTS:

Project 1: Depalletizer Safety Upgrade

– Result of incident. Funded out of EH&S budget

Project 2: Legacy PLC migration, adding HMI

– PLC Upgrade project was requested because the older PLC was obsolete (~20 years old) with no ability to acquire spare parts or support. Project was funded from “Automation” budget.

Time difference: 6 Months

Case Study 1 - Project 1: Depalletizer Safety Upgrade

Depalletizer Safety Upgrade (Two Machines)

Project Management $7,130 System Integration (Software) $11,040

Electrical Design $28,520 Mechanical Design $4,800 Electrical Hardware $36,064 Mechanical Hardware $40,000

Installation (Electrical & Mechanical) $40,000

Commissioning and Startup Support $23,080

Total $204,634


Project Details:• Add a secondary control panel for safety logic controller

and associated hardware.• Power to be removed on all elements controlling

hazardous energy • PLd/Category 3 safety architecture• Compliant with PMMI B155.1

Case Study 1 - Project 2: The PLC Upgrade


PLC Upgrade with Panelview Plus(Two Machines)

Project Management $5,060 System Integration (Software) $18,400

Electrical Design $20,240 Mechanical Design $0

Electrical Hardware $30,954 Mechanical Hardware $0 Installation (Electrical) $9,000 Commissioning and Startup Support $15,640

Total $99,294

Project Details:• Replace Modicon PLC with Controllogix 5000 platform

and add Panelview HMI for enhanced operator control• All of the new hardware will use Ethernet as the means of

communication within the machine and with the plant network.

Case Study 1 : Original Controls Solutions


Main Panel E-Stop

Master Reset

Elevator Left E-Stop

Elevator Right E-Stop

Pallet Stacker E-Stop

Safety Controller

Laser Scanner In-Feed (Top)

Pallet unloading (Bottom)

Upper PlatformPallet

ExitSide

Door 1

Side Door 2

Original Modicon PLC

Project 1: Safety Upgrade

New ControlLogix Added HMI

Project 2: PLC Upgrade

Added Control Panel

Case Study 1 - Combining Project 1 and Project 2


Independent Safety and PLC Upgrade (Two Machines)

Project Management $12,190

System Integration (Software) $31,440

Electrical Design $50,760

Mechanical Design $4,800

Electrical Hardware $77,018

Mechanical Hardware $40,000



Total $303,928

Combined Projects

SAVINGS

$8,533 30%

$18,864 40%

$32,994 35%

$4,800 0%

$77,018 0%

$40,000 0%

$46,550 5%

$29,040 25%

$257,799

$46,149 15.2%Savings just by combining projects

Mobilization Time:• Project

understanding• Kick-off meetings• Info gathering

Project Management Time: • Project planning• Scheduling• Financial

Monitoring












Total $303,928

Combined Projects

SAVINGS

$8,533 30%

$18,864 40%

$32,994 35%

$4,800 0%

$77,018 0%

$40,000 0%

$46,550 5%

$29,040 25%

$257,799


Programming:• Code modification

time (upgrade)• Code writing time

(new PLC)• Program Evaluation

Time• Debugging time• Quality control

time












Total $303,928

Combined Projects

SAVINGS

$8,533 30%

$18,864 40%

$32,994 35%

$4,800 0%

$77,018 0%

$40,000 0%

$46,550 5%

$29,040 25%

$257,799


Schematic changes:• Safety project

required modification of 12/15 existing drawings and creation of additional 14 new drawings

• PLC project required modification of all 15/15 drawings.

• Average 15 minutes per schematic modification and 45 minutes per new schematic.

• Average 30 minute quality check per set












Total $303,928

Combined Projects

SAVINGS

$8,533 30%

$18,864 40%

$32,994 35%

$4,800 0%

$77,018 0%

$40,000 0%

$46,550 5%

$29,040 25%

$257,799


Time:• Reduction in travel

time and expenses of only needing to be on site one time instead of two times.












Total $303,928

Combined Projects

SAVINGS

$8,533 30%

$18,864 40%

$32,994 35%

$4,800 0%

$77,018 0%

$40,000 0%

$46,550 5%

$29,040 25%

$257,799


Commissioning time:• Need for only one Site

Acceptance Test (SAT).• Decrease in

construction management time

• Decrease in system debugging time

• Reduction of overall on-site time



THE PROBLEM:

Separate safety and automation/operational projects minimize the ability to utilize integrated safety solutions, resulting in added expense for engineering

Case Study 1 : Original Controls Solutions


Main Panel E-Stop

Master Reset




Safety Controller




ExitSide

Door 1

Side Door 2

Original Modicon PLC

Project 1: Safety Upgrade

New ControlLogix Added HMI

Project 2: PLC Upgrade

Added Control Panel

Case Study 1 : Re-Engineered Solution


Main Panel E-Stop

Master Reset




Safety Controller




ExitSide

Door 1

Side Door 2

Original Modicon PLC New ControlLogix Added HMI

Replace with GuardLogix Controller

Added Control Panel

Case Study 1: Re-Engineered Savings


Case Study 1 Independent Combined

Project Management $12,190 $8,533 System Integration (Software) $31,440 $18,864

Electrical Design $50,760 $32,994

Mechanical Design $4,800 $4,800

Electrical Hardware $77,018 $77,018 Mechanical Hardware $40,000 $40,000 Installation (Electrical & Mechanical) $49,000 $46,550 Commissioning and Startup Support $38,720 $29,040

Total $303,928 $257,799

Re-engineered

SAVINGS$8,533 30%

$17,964 +3% 43%$32,194 +3% 37%

$4,800 0%

$76,018 +1% 1%

$40,000 0%

$36,550 +20% 25%

$27,540 +4% 29%

$243,599 Combined Savings:$60,349 19.8%

Newly Engineered Design: Additional $14200 Savings

Programming:• Reduction in

programming handshaking for Safety I/O status

Assumptions:• Programmer would not

need to learn another programming language for independent safety controller. Could add EXTRA cost

• No design changes








Total $303,928 $257,799

Re-engineered

SAVINGS$8,533 30%

$17,964 +3% 43%$32,194 +3% 37%

$4,800 0%

$76,018 +1% 1%

$40,000 0%

$36,550 +20% 25%

$27,540 +4% 29%



Reduction in Design:• No second panel

developed• Reduction in drawings

due to simplified design inside main panel

• Anticipated adding only 4 new drawings instead of 14 new drawings

Assumptions:• No design changes








Total $303,928 $257,799

Re-engineered

SAVINGS$8,533 30%

$17,964 +3% 43%$32,194 +3% 37%

$4,800 0%

$76,018 +1% 1%

$40,000 0%

$36,550 +20% 25%

$27,540 +4% 29%



Hardware cost:• GuardLogix hardware

costs slightly more than ControlLogix, Safety Controller, and associated electrical hardware

• No need for secondary panel and associated hardware


Installation cost:• Biggest reduction in

cost/time in installation of second panel

• Reduction in wiring inside panel

• Reduction in component installation









Total $303,928 $257,799

Re-engineered

SAVINGS$8,533 30%

$17,964 +3% 43%$32,194 +3% 37%

$4,800 0%

$76,018 +1% 1%

$40,000 0%

$36,550 +20% 25%

$27,540 +4% 29%



Commissioning Time:• Reduction in debugging

time with single Logic controller

• Reduction in debugging time with better diagnostic capabilities

• Reduction in SAT time through less fault testing and I/O checks (Functional testing remains the same)









Total $303,928 $257,799

Re-engineered

SAVINGS$8,533 30%

$17,964 +3% 43%$32,194 +3% 37%

$4,800 0%

$76,018 +1% 1%

$40,000 0%

$36,550 +20% 25%

$27,540 +4% 29%



Engineering Savings Expanded Further


How could these savings expand with a corporate imitative?

Case Study 2: 84 Palletizers, Depalletizers, & Stretch Wrappers across an organization

Number of Instances

(Out of 84)

Average Cost Per Incident

Average anticipated cost with an Integrated

Solution Per Incident

Overall Savings with an Integrated

SolutionFunctional modification requiring design change of safety system 51 $8,500 $5,000 $178,500 Modification to existing environment to support additional panel 17 $3,000 $0 $51,000



THE PROBLEM:

Conventional (Independent) Safety solutions can have a bigger impact on operational downtime and Overall Equipment Effectiveness (OEE)

Case Study 1: Project Downtime Evaluation


Safety Upgrade Project

PLC Upgrade Project

Total

Production Downtime

Production Downtime

Production Downtime

6 Days 4 Days 10 Days

CombinedProjects

Re-Engineered Solution

Production Downtime

Production Downtime

7-8 Days 7-8 Days

Estimated Project Downtime Savings:

2-3 Days!How much would this impact production?

Case Study 2: Integrated Safety Downtime Evaluation


IndependentSafety

Integrated Safety

PLANNED:Average Forklift entrances into palletizer/Depalletizer in 24 hour shirt

96

Average “Reset” time 15 Seconds 3 SecondsTotal Time Per Day 24 Minutes 4.8 Minutes

UNPLANNED:Full Machine Stop “Restart” time

15 Seconds to 15 Minutes

3 Seconds to 1 Minute

Integrated Safety Modifications:• Isolation of Entry Points

(Zoning)• Control awareness of

machine zones/cycles• Ability to “Pause”

motion V.s “Removal of Power”

Assumptions:• Operators are entering

the forklift at the appropriate times

• Zoning is cost prohibitive in independent safety solution

Case Study 2: Integrated Safety Downtime Evaluation


IndependentSafety

Integrated Safety

PLANNED:Average Forklift entrances into palletizer/Depalletizer in 24 hour shirt

96

Average “Reset” time 15 Seconds 3 SecondsTotal Time Per Day 24 Minutes 4.8 Minutes

UNPLANNED:Full Machine Stop “Restart” time

15 Seconds to 15 Minutes

3 Seconds to 1 Minute

Integrated Safety Modifications:• PLANNED Vs.

UNPLANNED are now the same

Assumptions:• Zoning is cost prohibitive

in independent safety solution

• Average downtime decreases, not just longest downtime event.

Case Study 2: Troubleshooting


IndependentSafety

Integrated Safety

Operator Troubleshooting Time 5-20 min 0-5 minTechnical Troubleshooting Time 20-90 min 5-30 min

Troubleshooting Methods:• Operators will review

status indicators• Operators will attempt

basic troubleshooting (e.g. reset system, open/close gates, etc.)

Assumptions:• Operators are well

training on the system• Independent Safety only

has basic alarm status indication.

• Times are considered “average” and only include minor repairs

Troubleshooting Costs:Direct Personnel Costs + Downtime Costs

Case Study 2: Troubleshooting


IndependentSafety

Integrated Safety

Operator Troubleshooting Time 20 min 5 minTechnical Troubleshooting Time 90 min 30 min

Troubleshooting Methods:• Technicians will evaluate

hardware and software• Technicians will attempt

advanced troubleshooting (e.g. Opening panel and connecting to PLC/Safety PLC, etc.)

Assumptions:• Technicians are well

training on the platforms• Times are considered

“average” and only include minor repairs

Troubleshooting Costs:Direct Personnel Costs + Downtime Costs

Taking advantage of the Trend: Savings

The Takeaways: • Lower capital costs by combining your

safety and automation/operational projects

• Lower your engineering costs through integrated safety solutions (Applies to upgrades or new equipment)

• Lower your operational costs with less downtime through advanced technologies

• Lower your lifecycle costs through lower costs on future modifications or changes


Questions?


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