JB Titus
Articles
Machine Safety: Are machine builders shipping unsafe machines?
Can a U.S. original equipment manufacturer (OEM) ship a machine without safety integrated into or included as part of the machine? Aren’t there regulations requiring machine manufacturers to provide machine guarding? An example of basic machine safety is an emergency stopping device, such as an e-stop.
Machine Safety: Risk of an actuator wired to general machine control versus safety controller
When deciding to apply a device to achieve a safety function, by default, that safety function should be achieved each time, actuated consistently and within a certain time period. For machine hazard mitigation, review these four points when considering risks and reliability of controllers versus safety controllers, defined by IEC 61508 (Functional safety of electrical/electronic/programmable electronic safety-related systems – Part 1: General requirements).
Machine Safety: ISO 13849-1 status, interlock switch safety
Upon reviewing a machine that has two interlock switches mounted to an access door, can you say that the machine is safe? Most industry experts today would say, "Probably not." Here's an explanation of why and the relevant standards.
Machine Safety: 12 hazards of unused machinery
Look at the 5 levels of hazard mitigation to help determine risk of a machine no longer in use. Consider the following 12 hazards of end-of-lifecyle machines. An unused machine is not necessarily safe.
Machine Safety: Identify machine safety standards for your business
Why is it important in the United States to identify machine safety standards for your business? See 6 ways standards help with machine safety.
Machine Safety: What is your safety elevator pitch?
In less than 30 seconds, can you tell me why I should care about your plans for exceeding industrial safety compliance? Are business benefits part of your answer?
Machine Safety: Safety and security combined
Some recent reports, cyber attacks have grown by 600% since 2010 costing industry around $400 billion a year impacting productivity, machine uptime and profitability. Machine safety automation also addresses productivity, uptime and profitability. Perhaps “safety” and “security” efforts should combine.
Machine Safety: Crossing the yellow line
Yellow line theory versus complacency: On a train platform few people cross the yellow line, without any specialized training, yet, in a manufacturing environment, accidents happen regularly after people cross the yellow line and even more formidable barriers. Why?
Machine Safety: Which takes precedence, a Type-B or a Type-C safety standard?
Understanding the hierarchy of Type A, B and C safety standards, isn’t a Type B safety standard to be considered precedent over a Type C safety standard?
Machine Safety and safety maturity: Are you safe without injuries?
International Labor Organization said every 15 seconds approximately 160 workers have a work-related accident, and one of those injured workers will die. So, does it make sense to keep detailed records of injuries to claim that an absence of injuries equates to the presence of safety? Know the 5 progressive steps to a strong safety culture.
Machine Safety: Do not tell employees that a safety compliant machine is safe
Just because you were particularly careful to purchase a new machine compliant to the latest machine safety standards and delivered with all the usual mandatory conformity marks like CE, UL, etc., you cannot tell employees they are working on a safe machine. Listen to OSHA and ANSI.
Machine Safety: Does a CE mark make a machine safe?
Machine safety discussions have risen to new heights with the advent of improved technology and the availability of Internet communication. Beware: pay attention to the details. An EU (European Union) discussion may not fully apply here in the U.S.
Machine safety standards: ANSI Z10 versus new ISO 45001 in late 2016
ANSI Z10-2005 is a machine safety concern and an opportunity, as recently discussed. I barely finished that blog post when I was informed about a brand new ISO Project Committee (PC) 283 tasked to take Z10 to the international stage. The new ISO 45001 is planned for approval in late 2016, but what would happen to the ANSI Z10-2012 safety standard?
Machine Safety: We haven’t finished assessing cloud computing; here comes the fog
Cloud computing has been discussed by all the big guys (Microsoft, Apple, Cisco Systems, IBM, Google, Facebook, HP, Sony, etc.) for several years. Some suppliers have already developed hardware products that only store data in “the cloud.” And, machine safety experts have begun assessing how, or even if, “the cloud” can play any role in providing machine safety.
Machine Safety: Which safety circuit design is required?
When considering safety circuit designs and compliance requirements, look at B level versus C level safety standards and their approval dates. See levels of machine safety standards graphic.
Machine Safety: Can one channel mitigate a Cat 3/PLd functional requirement?
Category 3 and 4 architectures typically call for a control reliable (that is, redundant) circuit design no matter what safe logic solver under consideration: safety relay, safety PLC, safe drive, and so forth. So why would there be any confusion?
Machine Safety: ANSI Z10-2005 is a concern and an opportunity
ANSI Occupational Health and Safety Management Systems standard ANSI Z10-2005 was updated, and the update approved on Sept. 5, 2012. This remarkable accomplishment created a national consensus standard for all types of organizations and companies regardless of size. A standard is not a guideline, and it carries compliance requirements. OSHA says ignorance of a regulation or standard is not an acceptable excuse.
Machine Safety: Wireless and cableless are similar but different
Know the differences, when considering machine safety, between wireless and cableless. As an analogy, is your hand held smart phone, with all its Internet, social media, photograph and movie capabilities, wireless or cableless?
Machine Safety: One design for OEMs, globally
Can’t original equipment manufacturers (OEMs) have one design for global customers? For at least 15 years we’ve heard about “global harmonization” of machine safety standards. Perhaps OEMs can finally enjoy the economies of scale of one design for global customers?
Machine Safety: e-stop devices versus safety devices
Safety devices and e-stop machine safety requirements consistently raise questions and merit review. The universal (and global) emergency stop device is not so universally understood. An e-stop is NOT a safeguarding device and certainly an e-stop is NOT a reset button. Review these e-stop device requirements according to machine safety standards.
Machine Safety: Verification is not validation
Know the 5 steps of the functional safety lifecycle. To perform functional safety and comply with safety standards like ISO 13849-1 and ISO 13849-2, design engineers need to know how to perform verification and validation measures; they are not the same step.
Machine Safety: IEC, ISO, ANSI, NFPA, SEMI, ASTM, ASME, NEMA machine safety compliance
The standards march: where are they headed? Which will litigation reference? For compliance? As international standards (IEC and ISO) are increasing worldwide adoption they are cited in U.S. domestic machine safety standards from ANSI, NFPA, SEMI, ASTM, ASME, NEMA, etc. Are these standards adopting or referencing IEC or ISO requirements for compliance?
Machine Safety: Integrated safety can learn from the 1960s
Machine safety thought leaders of tomorrow can learn from the evolution of machine guarding since the 1960s. Some safety was integrated even before PLCs.
Machine Safety: Networks can enable advancements in machine safety
Networks have seen significant advancements over the past 10 years to include safety certified networks. Have these technological achievements really advanced machine safety?
Machine Safety: Can machine operators be safe with Google Glass?
Special technology for machine safety can be applied in special ways to provide compliant machine safeguarding. Technologies such as Google Glass are starting to merge into human activity. How will safety behavior be impacted if employees are allowed to wear Google Glass near operating machinery?
Machine Safety: enhanced safety networks, the Internet of things, and autonomous safety
Does anybody remember HAL 9000, the computer that controlled the universe in the science fiction movie, 2001: A Space Odyssey? Is autonomous safety where we’re headed with networks and technology for integrated machine control and safety automation? [HAL 9000 was not OSHA approved.]
Machine safety standard merger: One global machine safety standard
In a few years, could we just have one functional safety standard? The world has two predominantly accepted functional safety standards for machinery: IEC 62061, Safety of machinery: Functional safety of electrical, electronic and programmable electronic control systems, and ISO 13849-1, Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design.
Machine Safety: what is the value of ISO 13849-1 for U.S. domestic compliance?
ISO 13849 clearly states that it is a standard for designers. If these designers work for U.S. original equipment manufacturers (OEMs), does the OEM have an enforceable legal requirement for compliance? Under the European Machinery Directive (MD), common opinion is no, but there may be exceptions.
Machine Safety: safety system validation and daisy divination
Take safety system validation seriously. Validation is substantiating that a required safety function is reliably achieved in a machine’s safety system. Validation is not the same as verification. Safety automation offers flexibility.
Machine Safety: Who is responsible for international standards?
A lot of work has gone into harmonizing international machine standards but a dilemma still exists – who is responsible? Ensure you know the answer.
Machine Safety: Do safety and security converge or intersect?
Machine safety and security each involve potential hazards that can result in personal injury, damage to property, and / or interruptions and unplanned downtime in manufacturing. While the outcome can be the same, machine safety and security differ in causal behaviors based on intent.
Machine Safety: Don’t play hide and seek with a safety program
Is your safety program like the game “Hide and Seek”? Or is your program “Top Down and Bottom Up” best-in-class machine safety? We all have a choice. Don't play games. Be proactive for machine safety compliance.
Machine Safety: Moving automation changes safety needs
Safety considerations change as the source of hazards transforms, such as on moving workstations like automated guided vehicles (AGVs). Even Boeing’s 787 Dreamliner is assembled on slow moving AGVs. How can guarding for operator safety accommodate changing hazard levels during assembly?
Machine Safety: Is your safety culture a top-down approach?
Safety culture is key to “best-in-class” performance. Engaging machine safety at the executive level daily permeates an entire organization. Are you seeing top-down benefits?
Machine Safety: Year over year safety automation growth outpaces general automation
Safety automation growth is outpacing growth in general automation. See these seven reasons and add your thoughts using the comment feature.
Machine Safety: 5 measures for making machine safety stick
Do you see continuous improvement in machine safety or backsliding? Use these five measures to emphasize and improve machine safety.
Machine Safety: What are your 2014 New Year machine safety resolutions?
Will 2014 be another year of the same or do you have a list of New Year resolutions for machine safety? Here are three machine safety ideas on which to focus this year, based on key OSHA violations.
Machine Safety: 13 terms to know for compliance with functional safety, ISO 13849-1
Knowing these 13 machine safety terms will help in efforts to comply with the international standard, ISO 13849-1: 2006, Safety of machinery, Safety-related parts of the control system. Many large companies have become early adopters of the new quantitative approach for designing machine control systems.
Machine Safety: OSHA’s top 10 cited violations for 2013
Are you very aware of OSHA’s top 10 citations for 2013? Is this because of your excellent safety culture and organizational diligence? Or, is it because you’ve been cited by OSHA?
Machine Safety: Has the era of cageless robots begun?
Could safeguarding become a requirement of the past? Baxter who? See the list of technology highlights in the past 40 years. Is OSHA keeping up with manufacturing technology innovations?
Machine Safety: Safe enough versus compliance, 8 compliance best practices
How does “safe enough” compare to “compliance”? It doesn't. Not having accidents for a period of time doesn't mean there isn't risk. See these eight machine safety compliance best practices.
Machine safety strategy: Stay the course or change?
Learn the four core behaviors of safety cultures. If a discovered hazard or an unexpected incident is only viewed as a problem, then problems could be distractions instead of enablers for continuous improvement or opportunities previously unseen.
Machine Safety: A new international standard for interlocking devices on guards – ISO 14119: 2013
Have you had unintended consequences of a “temporary defeat” or bypassing guard interlocks? Just-updated ISO 14119 “Safety of machinery – Interlocking devices associated with guards – Principles for design and selection" may help.
Machine Safety: Has Moore’s Law helped?
Moore’s Law states that the number of transistors on integrated circuits doubles every two years. While many consider this a joke, it’s not far off the mark looking back. Even so, has this rapid advancement in technology played a role in machine safety?
Machine Safety: You can have both safety and productivity
Solutions can deliver machine safety and productivity. Safety automation delivers a viable option to cabling discrete electromechanical components for safety compliance. And, by eliminating the need for cabling, safety automation can now help improve productivity.
Machine Safety: Thinking of bypassing an e-stop? Have you talked to an attorney?
Is it ever permissible to install a bypass switch or to disable an e-stop? For some reason, some Internet “safety forums” have had this continuing discussion. See the one requirement consistently missing from these international discussions. And ask these 4 questions.
Machine Safety: Industry 4.0 and how it could impact machine safety
The fourth industrial revolution could be well underway 10 to 20 years from now, say industry experts. The basis for this belief is a smart industrial intranet and Internet that connects machines and products using technologies like wireless and radio frequency identification (RFID) technologies to gain knowledge and improve efficiency without human intervention. Machine safety has a role.
Machine Safety: If only OSHA regulations are law, what are ANSI consensus standards?
OSHA regulations are enforced and considered as U.S. legal requirements for machine safety. Among thousands of consensus standards, it is not always clear which are significant for machine safety and could be an obligation for compliance.
Machine Safety: When workers use their own devices
Bring Your Own Device (BYOD) is the new rage. Articles describe BYOD and IT departments are scrambling. How can companies maintain control over machine safety and plant security?
Machine Safety: When should 2 mechanical safety switches be used on an access door?
European colleagues have many opinions about mechanical safety switches on access doors, especially in light of ISO 13849-1 and 2. Is this standard considered normative (mandatory) or informative in the U.S.?
Machine Safety: Discourage the defeating of safety interlocks
There are people who intentionally defeat safety interlocks. Doesn’t this increase risk and hazard level? See 6 proactive actions to discourage disabling of safety interlocks, along with one additional technology-based solution.
Machine Safety: Legal advice and safety automation projects
There are steps (or pot holes) for minimizing project-related risks from contract through completion. Safety automation priorities may vary.
Machine Safety: Near-miss events and residual risk
Are near-miss events and residual risk related when it comes to machine safety? Is there a machine guarding requirement specified for near-miss events?
Machine Safety: Design a safer machine with risk assessments
Understand why and how to conduct a risk assessment on a machine to improve the design by increasing safety and productivity. Note 6 reasons why to do risk assessments, and 8 steps to conduct a risk assessment.
Machine Safety: System integrators report shortage of safety resources
Those adopting safety automation are seeing reductions in machine downtime and easier maintenance, in addition to lowering risk for workers. With a shortage of industry talent remaining a concern, these are positive results.
Machine Safety: Has China caught the machine safety bug?
Rising costs of labor are fueling an increase in adopting automation in manufacturing to lessen the hiring of permanent employees, according to Control Engineering China. Does this focus on machine automation include safety automation?
Machine Safety: Domestic U.S. versus international standards
For machine safety, who needs to follow OSHA regulations, domestic standards, and various state and local requirements? Are you confused? Explanations follow.
Machine safety and layers of protection
Another study confirms the relationship between tasks performed and injuries and fatalities. Don't risk assessments find such relationships? Recognizing layers of protection can help.
Machine safety: Will applying OEE improve safety, compliance, and profits?
Safety culture that include overall equipment effectiveness (OEE) principles can improve safety performance and compliance to requirements? These two metrics can drive profits and establish the foundation for a sustainable safety strategy.
Machine Safety: A dashboard would help balance safety and compliance with profitability
What is a dashboard and how will that help my business? Is there a dashboard template to balance safety and compliance?
Machine safety: NRTL certified convergence of machine control and the safety-related parts combined
Does a Nationally Recognized Testing Laboratory (NTRL) certify machine control systems? OSHA has identified 15 organizations qualified to test and certify products for use in safety applications for the U.S. work force. There's a link between machine safety and productivity.
Machine Safety: For a safe machine, I’ll just install a small safety PLC
To mitigate a machine hazard, might it work to install one small safety PLC, then slave the other distributed standard PLCs to the safety PLC? Would that avoid the need for a risk assessment for the whole machine and create compliance? The answer is no. At least seven steps follow a risk assessment.
Machine Safety: Actuator controls versus machine actuators
Why is knowing the difference between a machine actuator versus an actuator control important? The hazard on a machine is what’s really important to reducing risk! Understanding two standards-based definitions can help.
Machine Safety: Are you farming out the designing in of functional safety component requirements?
Functional safety is supposed to be designed into machine design, but is it being farmed out for others to do? Are automation suppliers truly considering farming out the design and safety certification effort of integrating functional safety features into existing components? See four strategies and one caution.
Machine Safety: Robotic Industries Association updates safety requirements for robots
Robotic Industries Association (RIA) has announced its updated ANSI/RIA R15.06-2012 standard. This first update since 1999 (now harmonized with the international standard ISO 10218:2011) is a major step forward for users and manufacturers of robotics in the U.S.
Machine safety: Does ISO 13849-1: 2006 weight severity, frequency, and probability equally?
New quantitative requirements for designing safety-related parts of the control system (SRP/CS) have created many discussions. Even with new requirements from ISO 13849-1, this updated standard begins with the same old qualitative approach to determine the “goal” (Performance Level required- PLr) for any safety function, asking about severity, frequency, and probability.
Machine safety: Executives balance risks, profits
Industrial executives are engaged more than ever in operational risk oversight. This certainly includes machine safety.
Machine safety: PLC versus PAC, is there a difference for safety?
Is PAC the newest PLC? Is there less risk for machine safety in using one or the other?
Machine safety: Does effective grounding include ancillary hand rails, fences, and more?
How inclusive is effective grounding for machine safety? Should safe machine grounding consider hand rails, walkways, and protective fencing?
Machine safety: What is ambient air temperature and the relationship to safe operation?
How can the ambient air temperature range from -30 to +120 degrees Fahrenheit inside a manufacturing plant? The product specs call for certification at -5 to +30 degrees Centigrade for safe operation. Do the international machine safety standards address this?
Machine safety: Are most machines are intrinsically safe by design?
It is odd to think that anyone in the U.S. believes most machines are intrinsically safe by design. Yet, only three weeks ago I heard this comment spoken in a conference room. Honestly, this kind of statement needs a lot of scrutiny to understand the intended validity.
Machine safety: Incorporating functional safety as part of your machine safety plan, Part 4
When considering “functional safety,” look at what differs compared to other safety initiatives, consider U.S. versus international standards, examine conformance responsibilities, and think about what changes are needed, if any, as a manufacturer. Part 4 of 4 looks at how manufacturers should look at their machine safety programs in light of international safety compliance requirements.
Machine safety: Incorporating functional safety as part of your machine safety plan, Part 3
When considering “functional safety,” look at what differs compared to other safety initiatives, consider U.S. versus international standards, examine conformance responsibilities, and think about what changes are needed, if any, as a manufacturer. Part 3 of 4 looks at international safety emphasis and impact with OSHA.
Machine safety: Incorporating functional safety, part 2
When considering “functional safety,” look at what differs compared to other safety initiatives, consider U.S. versus international standards, examine conformance responsibilities, and think about what changes are needed, if any, as a manufacturer. Part 2 of 4 looks at U.S. vs. international safety.
Machine safety: Incorporating functional safety, part 1
When considering “functional safety,” look at what differs compared to other safety initiatives, consider U.S. versus international standards, examine conformance responsibilities, and think about what changes are needed, if any, as a manufacturer.
Machine Safety: What are fault exclusions?
Where did the term “fault exclusions” derive? Can you simply choose any fault to exclude? Who would ever exclude a fault while trying to provide employees with appropriate safe machine guarding?
Machine Safety: Serious machine guarding issues
Improper machine guarding is the result of... what? Could it be that there’s no universal cause for serious machine guarding issues? See below, six sources of machine safety issues.
Machine Safety: Is prevention through design enough?
U.S. consensus standards provide direction to suppliers on how to design in machine safety. Can users understand and comply with the additional requirements of ISO 13849-1?
Machine Safety: Can hand held devices play a role?
Wireless hand held devices (smart phones, tablets, pads, etc.), common in daily life, are emerging on the shop floor. Can they improve machine safety?
Machine Safety: Managing operational risk
Risk management has historically been a core element of business management to protect vital enterprise resources. Key executives now take a much broader perspective called “Managing Operational Risk,” with benefits for machine safety. See six data points or ways to measure.
Machine Safety: Does sustainability matter?
Effective, sustainable machine safety programs often contain these five high-level characteristics. Also see two more possible components of successful programs. These may help with your machine safety program’s consistency and focus over time.
Machine Safety: Protection is better than a cure
Can protection be an effective strategy for machine safety or does industry need a cure for hazards to protect employees? Here's why this questions should be asked daily.
Machine Safety: OSHA Top 10 Violations for 2012
See the top five reasons why machine safety has become even more important in the past 10 years. Also see the Top 10 OSHA violations for 2012: Machine safety account for four.
Machine Safety: More on shared responsibilities
Broad responsibilities of designing and building a safe machine from the supplier perspective were detailed in a November Control Engineering article by Steve Wright. Issues beyond that include additional shared responsibilities.
Machine Safety: Does multitasking provide an effective illusion of safety?
Is it possible to have everyone’s safety behavior in the factory exactly as it should be 24/7 without exception? Can safety performance always be at its peak? Are we capable of safe multitasking?
Machine Safety: Can end user companies comply with ISO 13849-1: 2006 without design engineering resources?
ISO 13849-1: 2006, an international machine safety standard, is written for individuals who perform design responsibilities for control systems. What are end users responsibilities?
Machine Safety: Is upgrading to solid state enough?
Moving machine guarding solutions to solid-state-based components from hard-wired components has been a persistent U.S. discussion since 2002. Are solid-state components enough to provide effective machine safety and personnel safety?
Machine safety: Confusion amuck, quantitative circuit design versus qualitative risk assessment
When talking about qualitative versus quantitative as they relate to machine safety standards and compliance requirements, are we talking about the risk assessment process? Or do we consider the process to engineer and mitigate hazards related to the Safety Related Parts of Control System (SRP/CS)?
Machine Safety – does new technology create new hazards?
When NFPA 79 changed by removing requirements for hard wiring machine safety devices in 2002, many automation suppliers introduced new safety rated devices for machine guarding. Domestic standards also have updated requirements to provide direction for use of safety rated devices. Do the new devices represent new hazards, such as lighted emergency stop buttons?
Machine Safety: Are you a chosen one?
A joint committee is merging two global machine safety standards (ISO 13849-1:2006, Safety of machinery -- Safety-related parts of control systems -- Part 1: General principles for design and IEC 62061:2005, Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems). Is this a good thing?
Machine safety: A social responsibility or KPI?
Is machine safety, as part of a corporate safety culture, focused at a social responsibility? Or is it part of the business culture as a key performance indicator (KPI)?
Machine safety: DANGER: Machine without brain requires yours!
Who really has the brain, the machine or the person? Whether it’s the operator, maintenance technician, set-up technician, engineer, or clean-up staff, the human brain has capabilities that surpass any brain on the machine.
Machine Safety: Are you staying on target?
Is changing my machine safety strategy necessary? What if your safety target has shifted? Have there been evolutional changes to industrial safety but your safety culture is mired in the past? Are there newer machine guarding solutions that are more cost effective? To stay on target consider updates to your safety culture and your machine guarding solutions practice.