Manufacturing In America 2016 The Why, What & How of Machine Safety. MIATTO, Detroit MI March 23/24, 2016

Transcription

1 Manufacturing In America 2016 The Why, What & How of Machine Safety MIATTO, Detroit MI March 23/24, 2016 Siemens Industry Inc. 2016

2 Siemens Safety Integrated Table of contents Safety What is it good for? Safety Does it have a value? Evolution of safety Safety Trends How to best increase safety! Safety best practices Safety applications & solutions Summary

3 Machine Safety What is it good for? The #1 reason: Based on Industry statistics & experience, it is always the right thing to do. It is essentially self evident Machine Safety is for protection of people, machines & environment The Complete Safety Solution

4 Machine Safety Typical Example seen in the industry A safety testing company committed to safety: Senior Most Manager stated that safety is very important But no safety manual People didn t know the safety rules No safety implemented But they did know that at the end of the month, revenue goal must be met!

5 Machine Safety Does Safety have value? Aberdeen Safety Report finds that top performing companies in safety have: 5-7% better Overall Equipment Effectiveness (OEE) 2-4% better uptime performance 50% less injuries

6 Machine Safety Does Safety have value? Over 60% of CFOs reported that each $1 invested in safety returned $2 or more Over 40% said productivity was the greatest benefit of an effective safety implementation Goldman Sachs Concludes, companies that properly address safety, perform better financially

7 Machine Safety What can machine safety do for you!! Optimize process reliability Simplify regulatory compliance Flexibility to meet project needs Reduce engineering & complexity Increase visibility into the process

8 Manufacturing In America 2016 Machine Safety Evolution Unrestricted, Siemens Industry Inc.

9 Machine Safety Evolution of Machine Safety PAST PRESENT FUTURE Use of nationally recognized standards only Hardwired safety Standalone safety Safety cumbersome Safety often bypassed Increased injury & risks Mix of national & global standards Acceptance of Safety PLC Safety Networks, Wireless safety Increased focus on safety standards Better diagnostics Merging of Global standards & partnership of standards bodies Intelligent safety devices Safety Integrated Increased focus on flexible manufacturing & productivity Innovative Smart Safety Systems

10 Manufacturing In America 2016 Machine Safety Trends Unrestricted, Siemens Industry Inc.

11 Machine Safety - Trends Which organizations standards do companies in the US mainly follow? North America (USA) EUROPE Unrestricted. Siemens Industry Inc Source Control Design Machine Safety, Dec Market Intelligence Report

12 Machine Safety - Trends Use of Safety components in USA (Source IHS) World Safety Market Outlook: Safety Technology is becoming more advanced as the market matures. Safety PLC s are growing more quickly. These products have particularly high adoption in United States, Germany and Japan. Integrated Safety with PLC s: Benefits can include lower overall cost of components This can be packaged with diagnostics, which with the advent of networking and Internet of Things (IoT) can benefit the end-user. Unrestricted. Siemens Industry Inc Source IHS Technology Safety Market Report 2014

13 Machine Safety - Trends American Market Forecast till 2017 (Source IHS). Source IHS Technology - Discrete Machine Safety Market Report 2014

14 Machine Safety - Trends ARC Machine Safeguarding Solutions 2014 Integrated Safety Highly integrated solutions along with networked architectures are becoming dominant choices for the high performance segment of the machinery market. This is mainly driven by the larger vendors. This integration minimizes the need for a separate safety system

15 Machine Safety - Trends What do all the trends lead to? An integrated safety solution in comparison to an autonomous safety solution Simply addition of fail-safe modules to the PLC Minimization of types and parts Standard and fail-safe automation only with one controller Standard know-how can be used 1:1 for safety engineering Uniform & advanced diagnostics for standard and fail-safe Safety logics realization via software instead of safety relay wiring Reduced wiring, easy adjustability, rapid commissioning, portability of fail-safe user programs with increasing requirements Standard and fail-safe engineering with only one engineering system Total costs of ownership Functionality Safety PLC s the faster, more cost-effective route to an optimum solution

16 Machine Safety How to best increase safety? 1. Risk Assessments, specifically accounts for (increases) production 2. Use applicable standards. 3. Risk Reduction, as applicable

17 Machine Safety - How to best increase safety? 1. Use Applicable Standards Standards Descriptions USA EU Comments International Organization for Standardization ISO , FS, Appl. specific std (PL), H-P ISO , FS, Validation ISO 12100, FS, Risk Assessments X - - X X X More guidance with safety calculations with the Safety Evaluation Tool International ElectroTechnical Commission IEC Generic Safety Standard IEC 62061, FS, Application specific std. (SIL) IEC Process Safety Standard X X X X X X More guidance with safety calculations with the Safety Evaluation Tool Occupational Safety and Health Administration American National Standards Institute OSHA 29 CFR 1910, Subpart O, Machinery and Machine Guarding Safety OSHA 29 CFR Control of Hazardous Energy (Lockout / Tagout) X X - - Siemens Safety Solutions Tested and certified by NRTL's (as per OSHA s requirement) ANSI B11 Series X - To be followed for application specific standards National Fire Protection association NFPA , Machine Safety NFPA , Burner Mgmt. Systems NFPA , Burner Mgmt. Systems X X X Compliance required, Wireless and Drives safety allowed Underwriters Laboratories UL NRGF covers ANSI / UL 508 / 1998 / NFPA79 and IEC Also new UL Functional Safety mark like TUV X - New UL Functional Safety Mark and recognition (similar to TUV- NRTL certification) Robotics Industries Association ANSI / RIA R , ANSI / RIA / ISO X X - X Required for all robotic machine safety applications Canadian Standards Association CSA Z434: Safety requirements for robots and robot systems - - Canadian requirement.

18 Machine Safety - How to best increase safety? 2. Risk Assessments The necessary steps towards a safe machine can be illustrated with a process chain. Risk assessment Risk reduction Proof Risk assessment Describe the machine Identify the hazards Evaluate the risks Risk reduction Define and evaluate the safety measures Design the architecture of the safety functions Implement a safety concept and put it into operation Proof Document the measures Carry out a validation Document results

19 Machine Safety - How to best increase safety? 2. Risk Assessments Are they necessary? YES! NFPA 79: Control Functions in the Event of Failure. The electrical control circuits shall have an appropriate level of performance that has been determined from the Risk assessment of the machine. ANSI B11.19: The protective stop circuit shall conform to the requirements of 6.1 or shall be constructed to meet the safety performance level (risk reduction) as determined by a risk assessment. ANSI /RIA 15.06: A Risk Assessment shall be carried out on those hazards identified in the hazard identification ANSI B11.0:2010 Safety of Machinery General Requirements and Risk Assessment ANSI ASSE Z244.1: Control of Hazardous Energy, Lockout / Tagout and Alternative Methods: Selection of an alternative control method by the user shall Unrestricted be based on Siemens a risk Industry assessment Inc of the machine, equipment or process.

20 Machine Safety - How to best increase safety? 2. Risk Assessments Risk assessment Risk reduction Proof The measure for achieved functional safety is the probability of dangerous failures, the fault tolerance and the quality that is to be guaranteed as a result of freedom from systematic faults. It is expressed in the standards using different terms In IEC 62061: Safety Integrity Level (SIL) In ISO : Performance Level (PL)

21 Machine Safety - How to best increase safety? 2. Risk Assessments Best Practice Review the Risk Assessment Control Risk Review every change implemented since the last review Review any additions to confirm they do not affect the risks Identify Risk Access Risk Ensure maintenance/repair do not affect the risks Review Controls

22 Machine Safety - How to best increase safety? 2. Risk Assessments Best Practice (When you receive a risk assessment..) Review as many times as needed Realize that there is information you need to know about/act on Machine Guarding to be installed Maintenance to be conducted annually Testing to be performed quarterly Proper training is also required Risk Assessment does not eliminate risk. Understand the level of risk and the assumptions

23 Machine Safety - How to best increase safety? 2. Risk Assessments Good risk assessments gone bad. Overestimating the effect of a mitigating or risk reduction measure Assuming a operator will do the right thing. Reducing the effect of a hazard based on a risk mitigation measure. Hazards don t change. If the hazard is death then the hazard is death. Measures put into place won t change that. Measures usually reduce the likelihood.

24 Machine Safety - How to best increase safety? 3. Risk Reduction & Implementation 1. Risk reduction Step 1: Safe design Step 2: Technical protective measures Step 3: User information on residual risks 2. Validation of the machine 3. Put in production Assuming the hazard cannot be eliminated, Implement Engineering Controls - Fail Safe, Machine Guarding, Safe shutdowns or reduced speed - Safe Torque Off, Safe Off etc.

25 Manufacturing In America 2016 Machine Safety Solutions Unrestricted, Siemens Industry Inc.

26 Machine Safety Innovative Safety Engineering Increase your OEE* So how does the Siemens product portfolio fit into the main 3 components Detection Evaluation Reaction SIRIUS position switches SIRIUS signaling columns SIRIUS EMERGENCY STOP pushbuttons SIRIUS standstill monitors ASIsafe safety modules Mobile Panels SIRIUS safety relays SIRIUS modular safety system MSS ASIsafe safety monitor SIMATIC fail-safe controllers SIMATIC ET 200 fail-safe I/O SIRIUS contactors SIRIUS motor starters SIRIUS compact starter SINAMICS G120/G120D SINAMICS S120 * OEE Overall Equipment Effectiveness

27 Machine Safety - Solutions Comparison of three evaluation types Features & Benefits Safety Relays Parameterizable Safety Relays Safety PLC s Safety functions 2 to 3 Upto 25 5 to large number Hard-wiring Extensive Very Extensive Minimal Mixed modes (Standard/Safety) Not possible Not possible Possible, also wireless safety, PC-based safety etc Functionality Difficult predefined functionality Difficult predefined functionality Easy based on software Safety Logic Very Difficult Very Difficult FBD & LAD Easy Modification Conventional Safety Functions Hard-wired Hard-wired TÜV-certified F-library Portability of fail-safe user programs No No Yes Easy Reproducibility of control cabinet Not easily reproducible Need to hardwire as part of solution Software only needs to be written once Trouble Shooting Difficult Cumbersome Faster (In-built display or HMI s) Device Replacement Takes longer Much Longer Fast due to permanent wiring & hot swapping (ET200SP) Safety Documentation Not available Not available Via Program Printout Expandability Difficult Difficult Easy (wired & wireless) Service Life Less Less Prolonged due to fewer parts

28 Machine Safety - Solutions Complete Safety Integrated Solution for all your needs PROFINET / PROFIsafe PROFIBUS / PROFIsafe SIMOCODE Pro Safety SIMATIC ET200 SP SIMATIC S7-300F SIMATIC IPC SIMATIC S SIMATIC ET 200S with Motor Starter SIRIUS Safety Switch ASISafe SIRIUS E-STOP Mobile Panel SINAMICS S120 Drive SCALANCE W Communication SIRIUS Safety Switch SIRIUS E-STOP ASIsafe Module Slimline Module SIMATIC ET 200pro with Motor Starter SINAMICS G120D Drive SINAMICS G120 Drive

29 Machine Safety - Solutions Easy to integrate into existing systems Upgrade the functionality of existing systems with minimal outlay Standard-Controller Safety relay Standard- Controller F-Controller Standard-Controller F-Controller PROFIBUS PROFINET PROFIBUS PROFINET PROFIBUS PROFINET PROFIBUS PROFINET IO IO F-Controller IO IO Initial situation Standard CPU and ET 200 IO External safety relay = CPU-CPU-Communication PROFINET: Controller <> i-device PROFIBUS: Master <> I-Slave Solution with separate F-Controller and F-IO Additional F-Controller and additional ET200 station with fail-safe IO modules Mixed solution Standard interface module of the ET 200 replaced by ET 200 F-CPU Extension of the existing ET 200 station with fail-safe Integrated solution Standard CPU replaced by F-CPU Expansion of the existing ET 200 station with fail-safe IO modules

30 Machine Safety - Solutions Innovation at its best Safety Controllers TIA Portal Safety Wireless Safety PC-based Safety BMS Systems

31 Siemens Safety Integrated Machine safety solution selection 3 Safety Functions 8 Safety Functions 25 Safety Functions >25 Safety Functions Without PC Graphical Editor Programmingg Language e.g., LAD/F-LAD Graphical Editor Cabinet-Free (IP 65/67) In-Cabinet (IP 20) In-Cabinet (IP 20) Cabinet-Free (IP 65/67) Safety Relays ASI-Safe Modular Safety System Fail-Safe Controllers Fail-Safe Controllers The Complete Safety Solution

32 Machine Safety - Solutions Everywhere! Automotive, Aerospace, Material Handling.. and more AUTOMOTIVE MATERIAL HANDLING STATUE OF LIBERTY AUTOMOTIVE CHEMICAL GLASS NORTH AMERICAN SAFETY REFERENCES WORLD-WIDE SAFETY REFERENCES AEROSPACE AMUSEMENT RIDES NON-INDUSTRIAL PHARMA CRANES OTHERS

33 Machine Safety Myth-busters Requirements Certified/Proven Centralized/Distributed Wireless Safety Scalable/Flexible Better Diagnostics Most common objections Used in the US & Globally Safety, cannot be used in central station Will lose SIL3, if wireless No downward compatibility Diagnostics have to be programmed Answers Siemens Safety Integrated Yes, TUV certified Yes & in distributed, as well No, Wireless up to SIL3 Both upward & downward compatibility Advanced diagnostics without additional programming

34 Machine Safety Summary - Key Trends in Safety Globalization of Safety Control Standards ISO/IEC Increased focus on Safety Design to Improve Productivity Transition from Electro-Mechanical to Electronic Safety Controls Safety Technology Integrated into Standard Automation Hardware Safety Networks, Safety being transparent Increased use of Wireless Safety Unrestricted. Siemens Industry Inc. 2016

35 Machine Safety Made Easy!!! Virtual Safety Symposium and more - Now on DVD Benefits: Latest updates on safety standards & compliance + Machine Safety Made Easy In collaboration with; OSHA, TUV, UL, RIA.. Innovative Siemens Safety Solutions Click on link below to order your DVD Implementation (Success Stories)

36 Siemens Safety Integrated Machine Safety Life-Cycle Support USA Siemens provides competent support throughout the entire machine safety lifecycle Support Safety Consultants Safety Core Team Safety Validation Implementation Siemens Solution Partners Safety Safety Functional Examples Safety Training Risk Assessment Training Products and Solutions Safety Products Safety Software Wireless Safety PC-Based Safety BMS Safety Education Machine Safety Standards Safety Webinars Newsletter Safety White Papers Siemens Safety Website Compliance OSHA Website Consensus Standards Risk Assessment Standard Safety Evaluation Tool - SET The Complete Safety Solution

37 Manufacturing In America 2016 Thank You!! MIATTO, Detroit MI March 23/24, 2016 Siemens Industry Inc. 2016

38 Unrestricted, Siemens Industry Inc.

39 SIMATIC Safety Integrated The future of machine safety John D Silva Safety Technology Manager DF / Factory Automation 5300 Triangle Parkway 30092, Norcross Phone: Mobile: john.dsilva@siemens.com siemens.com