Butler Professional Services, LLC Ray Butler - President Safety, Productivity and Risk Assessment Services For Industry Site Audits Guarding Assessments Efficiency Studies Task/Hazard Risk Assessments Safety System Design Analysis Safety System Design Validation Corporate Safety Standards Safety Programs OSHA Authorized Trainer Services Accident Investigations
Safety Management The primary objective of a safety management system is to provide a thorough understanding of the organization s risk profile, specifically as those risk affect people, property, process and the environment, and to provide the means necessary to proactively control those risk.
Factors to Successful Safety Programs Recognize Applications that Fall Below Minimum Good Engineering Practice Process Control Engineering Good Practice Safety Engineering Better Practice Safety Engineering Best Practice Safety Engineering B & 1 2 3 4 The Key Identifiers ~ 25% of User Applications Likely Fall Below Today s Minimum Good Engineering Guidelines No Safety Module Non-Safety Rated Components PLC Dependant, Edge of the Table Safety Distance Two Identical Machines /Different Levels of Safety Safety Mats Being Used as Primary Safety Devices (at less than 5 ft Ds) Single-Channel Circuitry Protective Rings Around E-Stop Actuators Rope-Pulls, THC s or E-Stops are the Only Safety Reach over, under, around or through Guards
Standards
Golden Rule OSHA 1910.212 (a)(3)(ii) (Point of Operation) The point of operation of machines whose operation exposes an employee to injury, shall be guarded. The guarding device shall be in conformity with any appropriate standards therefor, or, in the absence of applicable specific standards, shall be so designed and constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.
Today s Safety Environment The Best of Times Safety Technology; has never been better. has never been easier to implement. has never been more affordable/available. Offers complete prepackaged mix and match component solutions. Never has there been more resources available (how to information).
Today s Safety Environment The Worst of Times Today s Safety Environment; requires more proof of compliance. Holds decision makers responsible. Decision makers are being held personally and in some cases criminally liable. Many countries are requiring signatures on all hazardous equipment. ANSI will likely eliminate ALL grace periods from future standards.
SERIOUS CONSIDERATION APPLICATIONS: Seriously Consider the Following; Common sense - Are employees being exposed to controllable hazards? Industry recognition; Has industry addressed this application in either the standards or trade journals? History
IMMEDIATE ATTENTION APPLICATIONS: The Following may require Immediate action; Two virtually Identical Machines with Two obviously different levels of Safety. Safety Systems being bypassed. The panel has no signs of safety circuitry. THC s, or Pull-cords are the only safety devices.
Reasons for Investing in Safety Protection of Personnel Satisfy OSHA Requirements Proven to Benefit The Companies Bottom Line. Minimize Corporate Exposure/Risk. See Studies: Alcoa, Baxter, Tenneco, Motorola, Johnson & Johnson, Eastman Kodak, 3M,
Common Industry Recognized Abatement Methods
Typical Industry Recognized Abatement Methods ACCESS TIME > STOPPING TIME (Ds) = (K xt total) + Dpf Restricted Space Fixed Guard Interlocked Guard Two-Hand Control High Resolution Safety Light Curtain Low Resolution SLC Torso Detection 2 beam Perimeter Guard Safety Mats/Scanners
ACCESS TIME > STOPPING TIME Access Time > Stopping Time The essential application requirements for safeguarding devices result in the assurance that access time is always greater than stopping time. ACCESS TIME > STOPPING TIME To insure that access time is greater than stopping time, national, and international safeguarding standards typically incorporate these recognized industry guidelines. Ds =(K x Ttotal) + Dpf Ds - Minimum Separation Distance K Internationally recognized hand speed constants Ttotal Total stopping time, including the response time of the safeguarding device, and all interposing elements, through cessation of the hazardous motion or condition. Dpf Depth penetration factor internationally recognized adder to determine proper positioning of safeguarding selection.
Selecting Safeguards Safety Distance
Selecting Safeguards Fixed Barrier Guard A device or object that provides a physical boundary to a hazard that prevents exposure to an identified hazard. Generally, the first option is Barrier Guarding (Hard Guarding) Fixed
Selecting Safeguards Adjustable Barrier Guard A guard with provisions for adjustment to accommodate various jobs or tooling setups.
Selecting Safeguards Electromechanical (Positive-Opening) Courtesy of Allen-Bradley Courtesy of Banner Engineering Courtesy of Schmersal Courtesy of Bernstein
Selecting Safeguards Coded Magnetic Courtesy of Schmersal Courtesy of Banner Engineering Courtesy of Schmersal Courtesy of Telemecanique
Selecting Safeguards Courtesy of Jokab Courtesy of PILZ RF Transponder Actuator Courtesy of Schmersal Reading Head Courtesy of Bernstein
Selecting Safeguards Courtesy of Banner Engineering
Selecting Safeguards Courtesy of Sick Optic Electronic Courtesy of SICK
Selecting Safeguards Courtesy of LARCO Courtesy of LARCO
Two Hand Controls may not be acceptable as the sole means of personnel safeguarding. All others shall be safeguarded from hazards by design, or through the implementation of state of the art technology providing automatic protection (when feasible). NOTE: The safety system should not require a conscious act for safeguarding.
Access time < Stopping Time
Access Time > Stopping Time
What Safeguarding Device Should I use?
Determine which Industry recognized abatement method will allow for the most productivity. THEN. Is it safe? Is it Legal? Does it make Sense?
Cost of Safety Considerations Typical Range High Volume OEM $$$$ Low Volume User Hardguarding Cost/ft Additional Cost/door Engineering cost Cost/wiring Point 100.00 250.00 30.00 100.00 250.00 1,000.00 5.00 150.00 Cables, Conduit drops, Stands, Labor Rates, Testing frequency, Cost of Technology, down time, Floor Space, Maintenance. Rule of Thumb The cost of technology is usually about 1/3 of the overall cost of the installation.
Selecting Safeguards Barrier Guards vs. Safety Light Curtains
Which is most productive? Fixed Type A Safety Light Curtain Type B Which is least productive?
THC vs. Safety Light Curtains
THC vs. Safety Light Curtains
Automated Gate vs. Safety Light Curtains
Automated Gate vs. Safety Light Curtains
Probability of Failure Cost of Ownership Considerations All Safety Systems have to be checked periodically! Access Frequency Given the Same Application, Periodic Inspections/Training Should be Scheduled more Frequently for Minimum Practice Safeguarding than Best Practice Safeguarding
Customer Safety, Productivity and Efficiency Programs Establish Boilerplate Specifications for: Machine type, Circuit Types, and Integrity Establish Checklist & Frequency Review Periodically Safety Team Members and Roles Training on Essential Requirements Safety Bulletin Board Material Machine Guarding Checklist E-Stop Legend Validate and Review design Design of Safety System Minimize Wiring Points Checkout Procedures Installation Qualification Maximize Efficiency Identify Return-On-Investment And Productivity and Efficiency Opportunities Six Steps Implementation 24 Months Process Identify Hazards Perform Risk Assessment Establishing Priorities Identify Industry Recognized Abatement Methods Determine Feasibility of Potential Abatement methods Install Safeguarding Solution Training Blocks
Safety and Health Training Series Intro to OSHA S&H Programs Walking and Working Surfaces Egress and Fire Protection Electrical.ppt Machine Guarding Flammable and Combustible Liquids Hazard Identification & Safety Risk Assessment PPE Bloodborne HazCom National and International Standards OSHA, ANSI and ISO Standards OSHA Office of Training and Education
Selecting Safeguards Summary - Learn the ALL-IN cost - Identify ROI opportunities - ANSI Safety Standards are your friends - Demonstrate Due-deligence - Look for good manuals and instructions (Safety products are tending to be more and more comparable. If a supplier does not have a quality product, that supplier is not going to be in business.)
Butler Professional Services, LLC Ray Butler For application assistance or safety training tools on the following: Safety System Design Validation Corporate Safety Standards OSHA Authorized Trainer Accident Investigations Site Audits Guarding Assessments Efficiency Studies Task/Hazard Risk Assessments Safety System Design Analysis Safety/Compliance Programs E-stop Practices Two-hand Controls Tool Box Training Safety Team Tools Rbutler.bps@gmail.com PH: 612.670.5150
Questions
Good, Better, Best Safety Engineering for General Industry
Good, Better, and Best Safety Circuitry Given the Same Application, Periodic Inspections/Training Should be Scheduled more Frequently for Minimum Practice Safeguarding than Best Practice Safeguarding. Determine payback schedule Production time savings, (Reduced frequency $) with installation $ (Primarily Wiring $).
What are the Odds? Probability of Unsafe Failure Input Technology Expect a unsafe failure every "#" events 2.E-04 Spring dependant Mechanical switch dirty environment 5,000 2.E-05 Spring dependant Mechanical switch clean environment 50,000 5.E-06 Safety Rated direct acting mechanical switch 200,000 1.E-04 Single magnet Home security level switch 10,000 1.E-07 Triple Coded Magnetic 10,000,000 1.E-11 Intelligent self checking 100,000,000,000 1.E-05 Relay (max inductive load) 100,000 2.E-06 Relay minimum load 500,000 1.E-08 Redundant Relay (Max Load) 100,000,000 4.E-10 Redundant relays (Minimum Load) 2,500,000,000 1.E-11 Safety Light curtains Type 4 100,000,000,000 2.E-07 Safety Light Curtains Type 2 5,000,000 1.E-08 Cyclically Tested Type 2 SLC's 100,000,000 1.E-05 solenoid valve 100,000 1.E-10 redundant or fail to safe valve 10,000,000,000 1.E-06 IIIa THC 1,000,000 3.E-08 IIIb THC 33,333,333 1.E-08 IIIc THC w Redundant Relay Output Max Load 100,000,000 1.E-09 IIIc THC w Redundant Relay Output Minimal Load 1,000,000,000 1.E-11 IIIc THC w Redundant Solid State Output 100,000,000,000 million, billion, trillion, quadrillion
Probability of Failure Cost of Ownership Considerations What does it cost to test the system? (Lost Production) Access Frequency Machine value = $240.00/hr ($4.00/min) Testing Time = 1 minutes Cost per test =$4.00 ROI - How many test can you eliminate to justify a Best Practice solution?