safety system development process and configuration tools overview

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Safety System Development Process & Configuration Tools Overview

Chris Brogli – Global Business Development Manager, Safety


Session Purpose and Intent

This session is meant to outline the steps of developing

machinery safety solutions and tools that can help reduce

the time to develop, implement and start up a machinery

safety system.

Additional sessions (SF02, SF03, SF04 & SF05) break

this process down in more detail.

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 3

Agenda

Closing & Wrap-up

Sample Project Utilizing the tools

Selection, Design, Verification, Development & Justification Tools

Safety Life Cycle Utilization

Safety System Development Process



4

Common Safety System

Development Process

Machine review & hazard

identification

Product Selection

Safety System Design

Safety System Installation

Start Production

Proper Safety System Development Process

Risk Assessment

Functional Specification Development

Product Selection

Structure Selection

Design

Design Verification

Installation

Verification & Validation

Training

Operation & Maintenance


Most People Use the Common Approach!

5

Most people only analyze automatic operations!

Fact – 60 to 70% of all injuries occur outside of normal production activities.

Most people identify hazards and immediately select safety

devices/solution without considering the effects on productivity!

The number 1 cause of safety system failures is because the solution is bypassed.

This happens because it was not designed to accommodate job tasks.

Most safety systems that follow the common process result in significant

reductions in equipment utilization!

Most people have never been to a training session or have never read a machinery safety standard! This results in safety systems that are inadequate, ineffective & improperly designed.


The Proper Approach: A standards Based Methodology!

6

Both EN, ISO and ANSI standards require a systematic approach for safety

system development!

So which standard is right for you?

S1

S2

E1

E2

R1

A1

A2

A1 A2

A1 A2

A1

E1

E2 R2A

R2B

R2B

R2C

R3A

R3B

R4

S1

S2

F2

F1

a

b

P1

P2

e

c

d

P1

P2 P1

P2 P1

P2

F2

F1

b

c

d

OR

ANSI/RIA Method EN/ISO Method

Either is OK but the move is towards the ISO method because of new tools!


Development Considerations!

• What machine/machines are to be guarded? • What are the characteristics and limits of the

machine/machines? • What are the different modes of operation of

the machine/machines? • Who interacts with these machines during

normal and abnormal operation? • What are those people doing? • How does the machine need to function in

each mode of operation? • Are these any special system needs? • What type of diagnostics is needed? • What type of system performance is

needed? • What is the target efficiency rate of the

machine/machines? • What is the company specification? • What can be done to improve safety and

productivity?

What do I need to consider?


Agenda

Closing & Wrap-up

Sample Project Utilizing the tools





The Rockwell Automation Approach Follows the “Safety Life Cycle”

9

1. Assessment

The Machinery Safety Life cycle is a defined process that is followed to ensure that proper safety practices have been implemented!

5. Operate, Maintain & Improve

4. Installation & Validation

2. Functional Requirements

3. Selection, Design & Verification


Rockwell Automation follows the safety life cycle to

evaluate machinery safety solutions because:

• It removes uncertainty and eliminates omissions and errors! • It provide a repeatable process that leads to complete safety

solutions.

An idea without a plan leads to indecision, omissions and mistakes!

Rockwell Automation Safety Life Cycle

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 11

Step 1 in the Machinery Safety Life Cycle

is the Assessment!


1. Assessment




Proper safety system development starts here!


What is an assessment and how do I do it?

Step 1: The Assessment.

The Foundation of Safety System Development!

Machine Characteristics/Limits

Risk Evaluation

Hazard Identification

Risk Estimation

Risk Reduction

Risk Tolerable

OK

Too High

Risk Assessment Process according to ISO12100


Rockwell Automation Utilizes 3 types

of Assessments!

Safety

Service

Hazard / Guarding

Assessment Safety Assessment / Audit Team-Based Risk Assessment

Identifies Primary Hazards Assessment & Estimate Detailed Risk Assessment

Purpose Identifies guarding/ hazards for

immediate plant actions

Most common – provides report & estimates to

develop safety plans

In-depth analysis required for critical or special

machines

Service

Deliverables

• One Page Report identifying

hazards and “Risk-in” rating

only

• Does not include:

o Risk Out rating

o Cost estimation

o Pictures

• Assessment led by RA Consultant, limited

customer involvement

• Report per standard

Identification of primary hazards/tasks

List non-compliance issues

Risk In / Risk Out Rating

Mitigation Guarding and Controls

recommendations

Prioritized recommendations for safety

improvements

Photograph of critical identified hazards

(based on customer approval)

Cost estimate per machine

• Team-based assessment led by RA

Consultant for all machine life phases

• Report per standards

Identification of primary hazards/tasks

List non-compliance issues

Risk In / Risk Out Rating

Mitigation Guarding and Controls

recommendations

Prioritized recommendations for safety

improvements

Photograph of critical identified hazards

(based on customer approval)

Cost estimate per machine

• Mitigation Drawing

• Includes ergonomics review (slip, trip, and fall

hazards)

XX

Scalable assessment solutions to meet any need!



1. Assessment




Step 2 in the Machinery Safety Lifecycle is the

Safety Requirements Specification!

The SRS defines the functional requirements of the safety system!


The Main Reason for Developing

a Functional Spec!

The SRS defines my solution!

• It identifies how the machine is to operate in each mode of operation for each person that interacts with the machine!

• It identified special needs like: (Safe-speed/Safe-direction/Zone control/Etc.)

• It also identifies any special diagnostics and interface needs!



1. Assessment




Step 3 is the Selection, Design &

Design Verification Phase.

This step focuses on safety system design, product selection, circuit selection and design verification!


My assessment & requirements spec sure made this easy!

The Design Phase Includes Selection of Mitigation Techniques,

Products, Circuit Designs & System Structure Determination!

Design considerations: • What mitigation technique should I use? • What circuit structure should I use? • What safety products should I use? • What type of control system should I use?

(Relays/Controllers/PLC’s) • What type of special operations do I need?

(Zone control/Safe-speed/etc.) • Where are all of my safety devices? • What kind of interactions are needed for

auxiliary machines? • What kind of diagnostics do I need? • Should I use hardwiring or networked

systems?

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Copyright © 2007 Rockwell Automation, Inc. All rights reserved.

18

Possible Mitigation Techniques!

Design it out

Fixed enclosing guard

Monitoring Access /

Interlocked Gates

Awareness Means, Training and Procedures (Administrative)

Personal protective equipment

Most Effective

Least Effective

Hierarchy of Protective Measures

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Copyright © Rockwell Automation, Inc. All rights reserved. 19

Types of Categories (Structures)

CAT B/1 CAT 2

CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)


Product Selection Options!

The risk assessment tool identified the required performance level and

Category that is required for each part/portion of the machine.

Use products that meet the required performance level (PLr) and/or

the Category level as directed by the risk assessment.

Note: A safety system is made up of the following components:

Safety input devices/actuators

Safety control/logic devices

Safety output devices

Remember your weakest link sets your maximum system performance that can be achieved!


Select Devices to Make Complete Solutions!

Safety Controllers

Relays Systems

Safety PLCs

VFD’s

Contactors

Servo’s

Input Logic Output


Safety Relay/Safety Controller/ Safety PLC Selection Matrix!

Safety Relays • 1 Zone • Local/Hardwired I/O • Simple Safety Logic • 1 to 2 dual channel Inputs • 2 to 3 outputs

Safety Controllers & Expandable Relays • 1 to 3 Zones • Local & Distributed I/O • Simple & Complex Safety

Logic • 1 to 20 dual channel Inputs • 1 to 20 outputs • Basic Diagnostics thru PLC

Safety PLCs • More Than 3 Zones • Distributed I/O • Simple & Complex Safety &

Standard Logic • 1 to 100 dual channel Inputs • 1 to 100 outputs • Advanced HMI Diagnostics


Safety Output Selection!

Safety Contactors & Relays • Simple on/off control • Power control • Signal control

Safety Variable Frequency Drives • On/off control with the ability

to control & monitor speed

Safety Servo Systems • On/off control • Speed control • Direction control • Position control • Location control • Acceleration control • Decceleration control


Scalable Safety Solutions

Integration Continuum

Offering solutions that fit your needs, not ours!

Cost-effective Component Solutions Mid-Range Solutions Integrated Solutions

Low High

Simple connectivity Mechanical linked machine

Stand alone machine Low cost

Just enough control

Multi-axis motion Increased controller capabilities

Mix of mechanical and electrical controls Low engineering costs

Coordinated multi-axis motion Robotic feeders

Electronic line shafting Advanced connectivity

Advanced information capabilities

Components & Intelligent Motor Control Integrated Architecture

24 24 Copyright © 2011 Rockwell Automation, Inc. All rights reserved.


How do I verify my design!

The Design Phase Also Includes Design Verification!

Design verification considerations: • What do I need to do to verify my design? • What is meant by system structure? • What product information do I need? • Where do I get product safety data? • What verification tool should I use?


Design Verification Methods – Option 1 - Calculation Method

26

MTTFd Mean Time to Dangerous Failure Low 0 -10 Years Medium 10-30 Years High 30-100 Years

DC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous Failures

None DC < 60% Low 60 < DC < 90% Medium 90 < DC < 99% High DC >99%


a

b

c

d

e Per

form

ance

Lev

el

Designated

Architecture Designated






Architecture

Cat B Cat 1 Cat 2 Cat 2 Cat 3 Cat3 Cat 4

DC avg DC avg DC avg DC avg DC avg DC avg DC avg

<60% <60% 60% to <

90% 90% to <

99% 60% to <

90% 90% to <

99% 99%

Structure (Category)

Diagnostic Coverage (DC)

Reliability (MTTF)

Confirming PLr is Achieved by… Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (DCavg)


Design Verification Methods – Option 2 - SISTEMA Method

28

SISTEMA is a free design verification tool that is internationally recognized!


Design Verification Methods – Option 3 – SAB & SISTEMA Method

29

SAB utilizes SISTEMA for design verification but simplifies the process by using menus and questions!



1. Assessment




Step 4 Ensures that the System was Installed

Properly and that the System Functions as Intended!

This step focuses on ensuring that the safety system was installed properly and that there is a defined process for validating system performance!


How do I install my safety system?

Step 4 - Installation

• Installation considerations: • There should be specific instructions

regarding physical barrier installation! • There should be specific instructions

regarding safety product installation and wiring!

• There should be specific instructions regarding wiring methods and grounding!

• There should be specific instructions regarding panel fabrication and wiring!

• There should be specific instructions regarding signage installation and location!

• There should be specific layout drawings showing a routing, mounting and installation instructions!

• There should be specific electrical schematics regarding terminations & connections.


How do I validate my safety system?

• Validation considerations: • There should be specific instructions

regarding the validation of for each safety function! • This means that each safety input, logic

& output device must be tested to ensure it functions as intended!

• This means that each combined function of input/logic/output must be tested to ensure that it functions as intended!

• This means that each programmed function is validated to ensure it functions as intended!

• There should also be specific instructions regarding fault injection to test the safety ! • Common testing methods include:

• Shorting wires, breaking connections, removing wires, etc.

Step 4 Continued - Validation



1. Assessment




Step 5: Operate, maintain and improve ensures that the

system is operated properly and that the system is maintained

to ensure continued effectiveness!

Step 5 focuses on ensuring that the safety system is operated properly and maintained to ensure continued effectiveness!


How do I operate my machine?

Step 5 – Operate, Maintain & Improve

• The should be training for all personnel that will be interacting with the machine.

• The training should include: • Intended use • Safety system components training • Normal operations • Safety system operations


How do I maintain my safety system?

Step 5 – Operate, Maintain & Improve

• The standards say that periodic testing should be done to verify proper system functionality. (There is no defined period or timeline that is suggested)

• The standards also require additional assessments after machine modifications. This might include: • Program changes • Safety system use • Hardware changes • Machinery changes • System modifications



1. Assessment




The Machinery Safety Life Cycle Never Ends!

The cycle never ends. The system must be re-evaluated anytime modifications occur and each step must be followed!


Agenda

Closing & Wrap-up

Sample Project Utilizing the Tools





Rockwell Automation moved into the number 1 provider of safety solutions because of investment in products, services & tools that help customers maximize performance!


Rockwell Automation’s Investment in Technologies!

• Integrated Safety Platforms

• Safety Instructions & Applications

• Functional Safety Compliance

• Embedded Safety Capabilities

• Advanced Safe Motion Functions

• Integrating Control, Safety & Motion

• CIP Safety for DeviceNet & EtherNet/IP

• Low Cost Safety Networks

• Dual Port EtherNet/IP

The broadest portfolio of safety products in the industry!


Rockwell Automation’s Investment in Services!

Assessments Arc Flash

Analysis

Hazard Risk LOTO HAZOP

Validation Safety circuit

analysis Machine stop

time services Conformance

audits Safety system

validation

Compliance Consulting CE

conformance Functional

safety (ex. ISO 13849-1 and IEC 62061, ISO, ANSI, IEC, CE, OSHA, NFPA, CSA, AS )

200+ Safety Professionals Available Globally 100+ Machinery Safety Certified Resources 80+ Process Safety Resources Over 200 Training Courses for help customers develop competency

30 + RA Safety Professionals 3 RA Safety Partners – 20 Resources

4 Safety Professionals

20+ RA Safety Professionals 12 RA Safety Partners – 24+ Resources

20+ Safety Professionals




Training TUV Certification Risk

Assessments Safety Standards Safety Products Arc Flash LOTO

Integration / Start

Up Circuit/logic

design Installation Arc flash

remediation MCC Arc Flash

upgrades Project

Management

Remediation Solutions Complete

Turnkey Systems

The most complete suite of safety services in the industry!


Rockwell Automation’s Investment in Tools!

Safety Return-On-Investment Tool Find out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.

Safety Functions

Safety Functions Program The Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.

SAB Safety Automation Builder The Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.

Safety Accelerator

Toolkit

Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.

Connected Components

BB

Connected Components Building Blocks These building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the

ProSafe Builder

ProSafe Builder The ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.

The broadest suite of safety tools in the industry!

http://safetyroi.avidcom.com/








Safety System Development Tools

42

SAB Safety Automation Builder The Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation.

ProSafe Builder

ProSafe Builder The ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.


What is Safety Automation Builder (SAB)?

SAB is a new tool designed to help develop complete safety system solutions. These solutions include conceptual layout drawings that includes zones, physical guards, hazards, access points and the products used to protect personnel.


SAB helps tie the two sides of Functional Safety together

by providing a method to select the safety products that

are required to complete a safety solution!

Risk Assessment Design Verification

Determines (PLr) Confirms PLr Achieved


Qty Catalog Number Description DS List Ea Typical Delivery

1 445L-P4E0600FP Micro 400 Safety Light Curtain, Pair, Res 30mm, Pt Ht 600mm E8 $ 1,220.00 Preferred

2 445L-AC8RJ5 M12 to RJ45, 5 meter E8 $ 26.30 Preferred

1 440R-ACABL2 Ribbon cable 10 pin for 2 extenstion E8 $ 36.46

1 440R-P226AGS-NNR MSR42 Multi function Controller for GuardShield Light Curtains E8 $ 507.00 Preferred

1 440R-D22R2

Guardmaster Safety Relay, 2 Dual Channel Universal Inputs, 1 N.C. Solid State Auxiliary Outputs E8 $ 402.99 Preferred

1 100S-C37EJ14BC MCS 100S-C Safety Contactor, 37A, 24V DC (w/Elec. Coil), Bifuracated Contact B7 $ 411.07

1 1754-L28BBB GuardPLC 1200 - Packaged Safety Controller, 28 I/O D5 $ 6,120.60

1 1753-DNSI GuardPLC DeviceNet Safety Scanner D5 $ 1,141.30

2 1753-IB16 Digital Input Module, 16 Inputs, 24V DC D5 $ 1,787.70 Preferred

SAB – The Complete Safety System Design & Verification Tool that Leaves Customer with a Complete Bill Of Material!

Complete Safety System Layout

Performance Level Verification

Complete Bill of Material


4

6

ProSafe Builder - Trapped Key Configuration Software

The software will allow users to

layout trapped key systems in a

systematic method that shows a

flow view of configured and

selected products.

The comprehensive trapped/captive key tool on the market!


Safety System Investment Justification Tool

47

Safety Return-On-Investment Tool Find out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return-On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.









Justification Of Safety Investments

48

So, how do I justify a safety investments on my machine?

A. Based on the costs of an incident that could be avoided

B. You don’t; Just do the minimum to comply with a standard

C. Based on the potential for productivity improvement

D. Based on the fine from a non-compliance finding

E. Perform an ROI

Answer: “E”

Good News! Rockwell Automation Can Help With A Safety ROI Calculator

“But how do I calculate a Safety ROI?”


What is the Safety ROI Calculator Tool?

49

The industries only return on investment tool for safety projects!


ROI Example Output!

50

The Safety ROI tools helps customers justify safety projects based on

project cost and injury avoidance calculations!


Safety System Design Tools

51

Safety Functions

Safety Functions Program The Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan.

Safety Accelerator

Toolkit

Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates.

Connected Components

BB

Connected Components Building Blocks These building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 52 52

Safety Life Cycle

5. Maintain and Improve

1. Hazard or Risk Assessment

4. Installation and Validation

2. Functional Safety System Requirements

3. Design and Verification

Identify Hazards & estimate the associated risk

System Architecture Safety critical circuit design Guarding design Validation protocol

Based on: - Risk Assessment - system performance - applicable s standards

Final site assembly Commissioning/Validation Training Final Risk Assessment Validation

Verify that system requirements operate within specified parameter for Production and Safety Preventative maintenance and system upgrades

Safety Functions Help Customers Move Beyond the Risk

Assessment with Complete Rockwell Solutions!


Safety Functions are the Building Blocks of

Machinery Safety Solutions!

Risk Assessment Model & Confirm PLr

Determines (PLr) Confirms PLr Achieved

To Realization and PL evaluation


The More Complicated the Machine the More Safety Functions You Need!

E-Stop Device 1

E-Stop Device 2

Light Curtain 1

Door Interlock 1

Logic

Output 1

Output 2

Output 3

SF1

SF2

Logic

SF3

SF4 Output 4 Logic

Logic

Large and complex machines may require multiple safety functions to provide a complete machine safety solution. Safety function documents are 1 way that Rockwell Automation can help!


• Safety Functions include GSR relay solutions and GuardLogix solutions.

• The initial 6 Safety Functions launched October 1st.

• Two additional ones launched in February.

• 13 additional Safety Functions will be added by the end of 2014!

• Each safety function includes a functional specification, a electrical

diagram, a program or configuration document, a SISTEMA verification report and a verification & validation document to help users develop safety solutions quickly, easily and accurately with minimal effort.

Introducing the Safety Functions Library


Sample Safety Function

Safety Function: Emergency Stop

Products: Light Curtain / GuardLogix Safety Rating: PLe, Cat. 4 to EN ISO 13849.1 2008

.

Introduction

Important User Information

General Safety Information

Safety Function Realization

Setup and Wiring

Configuration

Programming

Falling Edge Reset

Calculation of PFHd

Verification and Validation Plan

Additional Resources


IA Safety Accelerator Toolkit

Development Tools and Quick Start Guide

Simplified Wiring

Preconfigured Logic

Quick Start Manual

Preconfigured HMI


IA Safety Accelerator Toolkit Safety Application Examples

58

Example Code

I/O Configuration

Diagnostics


Instruction Faceplates

59

Want to troubleshoot safety instructions from

your HMI?

NOW YOU CAN

Display the instruction as the Function it is

performing.

Estop

Light Curtain

Light Curtain Muting

Etc.

59


Safety Accelerator Toolkit

Guard I/O Status and Diagnostic Faceplates


Safety Performance Tools for GuardLogix

TUV Recognized Analysis Tools

Single Channel Safety Reaction Time Tool

Network Reaction Time Tool


GuardLogix Safety Estimator

Safety Tool to help estimate system performance and network configuration.


Connected Component Building Blocks for Safety

63

Pre-designed Building Blocks with source code, drawings and quick-start guide to help you develop safety solutions!


Implementation & Documentation

64

Okay Here’s What We Accomplished So Far…

Identified the Hazards and Documented Our Risk Assessment

Developed the functional specification to Mitigate the Risks

Designed the Safety Solution & Selected Components

Verified the design to confirm the achievement of the required system

performance.

Performed an ROI analysis demonstrating the value of the safety system

Leveraged example code, faceplates, wiring diagrams etc.

Complete documentation for your safety solution!


Agenda

Closing & Wrap-up

Sample Project Utilizing the Tools





The Safety Process – What do I do?

66

Ok, I need to make my machine safe. Now what?

Four Questions To Navigate the Jungle

What do I need to do?

What are my options?

How much do they cost?

Which option is right for me?

Let’s Look at a Couple of Options…


Let’s Look at a Sample Machine!

67

We are going to use the safety tools to develop a safety solution

utilizing Safety Automation Builder. This will leave us with a concept

drawing, a design verification and a complete bill of material.

We will use the ROI tool to help the customer justify the project.

We will then search for solutions for the selected products using safety

functions, safety accelerator toolkit and connected components building

blocks.


Machine Description

68

Infeed Conveyor

Outfeed Conveyor

Rotary Table

Label P&P

Label Feeder

Hot Glue Gun Product


Step 1 – Risk Assessment

69

We are going to develop a risk assessment utilizing the ISO12100

evaluation method.

S1

S2

F2

F1

a

b

P1

P2

e

c

d

P1

P2 P1

P2 P1

P2

F2

F1

b

c

d


Step 1: Details

70

Normal operation

Maintenance

Set-up

Adjustment

Change-over

Start-up

Decommissioning

Etc.

Identify the hazards and associated risks! Develop a functional specification that outlines how each hazard needs to be protected for each mode of operation. Thermal Hazard

Crushing Hazard

Pinching Hazard

Pinching Hazard

It is estimated that 60 to 70% of all injuries happen outside of normal production activities

yet most people spend 90% of their efforts around designing for production activities!


Show how the ISO12100 risk methodology is

used to determine the required system

performance that is to be implemented.


Step 2: Write a Functional Specification

72

The assessment defined the task and associated hazards and the required

system performance that is required.

The function specification will determine the required safety functions, their

design requirements and the type of functionality that is needed for each

mode of operation for each person that interacts with the machine.


Define Our Safety Functions

When Door Opens in zone #1, tray packing stops, zone #2, tray forming continues.

Safety Function: Safety related stop function

initiated by a safe guard

Stopping hazardous movement

Triggering Event: Opening of guard door

Zone #1 Zone #2

Follow this Process for Every Safety Function in Every Machine Mode!


Show how to develop a functional specification.


Step 3: Develop a safety project utilizing Safety Automation Builder

75

This screen shot shows the layout drawing with identified hazard locations and access points that need to be protected!


Users can now start the safety selection process by selecting

input, logic and output devices for each identified safety need!

76

This screen shot shows the layout drawings with the selected safety devices!


Users can view the selected safety devices for each access

point by clicking on the table view!

77

This screen shot shows the devices that were selected for each safety function!


Users can verify their design by exporting the SAB file to

SISTEMA for design verification! This is a sample report.

78

This screen shot shows the safety design verification report from SISTEMA!


Completed Bill of Material from ProposalWorks & SAB!

79

This screen shot shows the completed bill of material for the labeler machine safety system!


Show how to develop an SAB project.


Now we Have a Price! We Need to Justify the Investment!

81

We will use the Safety Return on Investment Tool to justify the project

based on projected reductions of injuries and productivity enhancements!

Let’s calculate our savings and ROI for this machine example!


Show how to develop a justification

report using the ROI calculator!


The Next Step After Selection, Design Verification & Justification is Design!

83

Now we need to start making schematics, developing programs and

configuration documents. We will guide you to locations that can help!

The Safety Functions documents are found on the safety resource center!


Let’s search for the applicable safety functions!

84


An Additional Tool that Can Help is the Safety Accelerator Toolkit

85

Safety Accelerator Toolkit

The Safety Accelerator Toolkit can be found on the safety resource center or by asking your local Rockwell distributor!


Let’s search for the applicable safety accelerators!

86


An additional tool that can help is Connected

Component Building Blocks for Safety

87

The Safety Building Blocks can be found by asking your local Rockwell distributor for a CD!


Let’s search for the applicable safety building blocks!

88


PUBLIC INFORMATION

Summary


Rockwell Automation - the Global Leader in Safety (Services/Products/Solutions)!

Best in class assessment services to help you to determine

safety system needs!

Safety Design Tools and resources to help engineers and

designers with safety system development.

Products selection and design verification tools to helps

engineers select product quickly and accurately.

Installation and start-up services to help meet productivity and

start-up needs.

Validation services to ensure that the safety system operates

as designed and constructed.

Preventive maintenance development services to ensure the

safety system continues to operate properly.


We care what you think!

On the mobile app:

1. Locate session using

Schedule or Agenda Builder

2. Click on the thumbs up icon on

the lower right corner of the

session detail

3. Complete survey

4. Click the Submit Form button

91

Please take a couple minutes to complete a quick session survey to tell us how we’re doing.

2

3

4

1

Thank you!!


PUBLIC INFORMATION

Questions?

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