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PRODUCTIVITY. FLEXIBILITY. SAFETY.Enabling safety in automation
www.klinkmann.com6 / 2011
Enabling you to achieve
productivity and flexibility...safely
2
It goes without saying that you want to keep your employees safe.
You also want to operate your equipment at peak efficiency.
Clearing jams, reloading parts, inspecting material and adjusting
components are just a few of the tasks that operators and maintenance
staff perform on your equipment on a daily basis. Keeping them safe
while maximising the efficiency of your equipment is critical to your
success in a globally competitive market. By better aligning the behaviour
of the safety system with tasks that are performed, you can improve
employee safety, and in many cases increase productivity.
Today’s contemporary safety solutions allow you to
achieve this, flexibly and safely.
How can you minimise
costwith your safety approach?
How do you achieve
complianceto legislation requirements?
Are you achieving safety and
productivitywith your safety investment?
www.klinkmann.com6 / 2011
33
“Our co-operation with Rockwell Automation® goes backto the mid-90s, and has developed into more than theusual customer-supplier relationship. We work togetherclosely, and always have a good dialogue about pros, cons and costs before we choose the solution that worksbest for us and for our customer.”
John Christiansen
Manager, Electrical Department, Gram Equipment
Contemporary safety solutions
4
What is machine safety?The answer to this is essentially self-evident: providing a machine
environment which protects people from hazards and in many
cases also protects the machine’s operation from misuse. Less
obvious is how safety systems can be designed and implemented in
order to improve – rather than restrict – capability.
Conventionally applied safety Historically, the approach to safety was simple – stop
a machine when a demand on the safety function is detected. This
strategy was effective from a safety viewpoint, but had clear
implications for productivity. Conventional solutions sometimes did
not take into account other functions conducted on a machine,
such as maintenance, commissioning, and cleaning.
Often to achieve these functions quickly, safety systems may have
been bypassed.
Contemporary applied safetyThe introduction of global functional safety standards has
resulted in the development of cost effective integrated safety
strategies. The use of newer contemporary technologies is now
accepted and documented in such standards, allowing
equipment manufacturers and the users of such equipment to
integrate safety in order to achieve what the machine is there to
do; Produce...safely. This means that safety systems are better
aligned to the needs of operators and maintenance staff, so that
the need to bypass the system is eliminated and tasks are
performed more efficiently and safely.
“Safety and production can go hand in hand,” Quigg says.“We’re proving it here. I’m proud of our ability to engineer asolution that helps meet and exceed our customers’expectations. With the help of Rockwell Automation, wewere able to provide our customers with a safer place towork, increased production and reduced equipment costs.”
Joe Quigg
Vice President at Quigg International
www.klinkmann.com6 / 2011
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So why invest in contemporary safety solutions?When assessing your machine or process from a holistic viewpoint,
you will no doubt be considering the following:
ComplianceHow can I achieve compliance to
legislation requirements?
CostHow can I minimise cost?
ProductivityHow can I get the machine to be
as efficient as possible?
These questions, for many manufacturers and the machine builders
who supply their equipment, are understandably important. This is
why new safety standards take into consideration more than just
the safety functionality. As safety legislation has evolved, standards
have developed to assist industry in achieving not only compliance,
but also allowing manufacturers to achieve productivity and
flexibility... safely.
Utilising contemporary technologies and experience in
Automation Solutions from Rockwell Automation, you can be
confident that the solutions you adopt will be productive,
flexible, compliant and cost effective.
The goal is not just to increase safety... it is to increase value and
overall productivity.
www.klinkmann.com6 / 2011
Understanding compliance
6
Whether you’re an end-user, a machine builder or an integrator, you
need to be sure you are complying with relevant safety legislation.
Utilising the latest safety standards can help achieve this, but that’s
not always easy, as both have evolved rapidly in recent years and
can be challenging to absorb.
The Machinery Directive The Introduction of the European Machine Directive in 1995 had a
radical impact on the way machine safety systems were designed
and implemented. The new Machinery Directive – 2006/42/EC,
which becomes applicable on the 29th December 2009, will have
similar impacts as it is associated with new standards, one of which
replace EN 954-1, the standard that measured relative levels of risk
through the use of Categories.
The direct replacement of EN 954-1 is EN ISO 13849-1:2006 (safety
of machinery – Safety-related parts of control systems – Part 1:
General principles for design). This standard utilises Performance
Levels (PL) as a preferred measurement of risk / system integrity and
is an easy transition for engineers who are familiar with EN 954-1.
The Machinery Directive is also associated with IEC/EN 62061
(Safety of machinery – Functional safety of safety-related
electrical, electronic and programmable electronic control
systems ). This standard covers safety related systems that may
be more complex and utilises safety Integrity Levels (SIL) as a
method of measurement.
You can choose to use either standard as both offer guidance in
development of safety systems. As a general consensus, it is
recognised that PL can offer the easiest transition between safety
Categories and SILs.
www.klinkmann.com6 / 2011
What do I need to know?EN 954-1 (Categories) only remains valid until end of December
2009. After this time for all practical purposes the Machinery
Directive – 2006/42/EC will require re-classification of safety related
control solutions to SIL or PL. These assessments require more
information and calculation than Categories, but they allow more
flexibility and use of new safety technology.
A technical file is also required to demonstrate conformity to the
machinery directive. This is required from machine manufacturers
or companies that are building or significantly modifying machines.
It is intended to help document the methods used to achieve
safety compliance.
Not too much, not too little The benefit of adopting one of the two new standards is flexibility.
Although the initial effort to reassess the machine or process may
be challenging, the outcome may help adopt contemporary safety
solutions which can offer the right level of safety; without over-
engineering the system or wondering if the safety solution you
have implemented is enough.
Who can help me?By working with Rockwell Automation, you have the support of a
global organisation with extensive understanding of legislation,
standards, and the methodology to achieve conformity.
Rockwell Automation can assist you with:
• Legislation and standards guidance
• Risk assessment and risk reduction planning
• Safety system design, validation and analysis
• Conformance audits and technical file
documentation assistance
• Training and field service support
• Turnkey Risk Assessment facilitation
and report generation
The key challenge, says Kelly, wasensuring that operation of the pressremained safe. “It was very easy for meto say exactly what I wanted, but wehad to make sure it fit within the safetyconstraints. Rockwell Automationrecommended a risk assessment becarried out, and we thought this was agood idea. The outcome reinforced andclarified the safety issues and gave us amanageable project with specific goals.”
Paul Kelly,
General Manager, Shepparton NewspapersPrinting Division
7www.klinkmann.com6 / 2011
8
For all businesses, the minimisation of cost
is a major issue. This means not merely
capital cost, but – even more importantly–
the total cost of ownership. Although the
implementation of a contemporary
machine safety strategy may require an
investment, and perhaps a significant
one, it can also play a major role in
reducing overall cost.
How do you measure the cost of your safety investment? Unless you’re implementing a suitable
contemporary safety strategy, the
chances are that your safety system is
costing more than it should. Consider the
overall cost, from design, through
commissioning, to use and maintenance
when assessing investment.
Some common examples where
unforeseen costs may reside are:
• Hard-wired safety circuits – any
change in requirements during the
machine’s lifecycle may require a
significant redesign and cost
• Poor diagnostic information –
if you are troubleshooting issues
without appropriate system
diagnostics, your MTTR (Mean Time To
Repair) can be lengthy and costly
• Independent safety and standard
circuits – Depending on the level
of safety required, separating your
automation and safety systems can be
expensive, troublesome and complex
Controlling cost
When accidents occur, thehidden direct and indirectcosts may easily outweighthe cost of an integratedsafety system.
www.klinkmann.com6 / 2011
What is your total cost of ownership?Cost of ownership is a critical factor in any plant. A system which is
prone to safety breaches or which is frequently down will have
higher than optimum cost of ownership. That’s where an integrated
safety system can help. By minimising risk of accident and
downtime, it will help you reduce the cost of lost production due to
accident investigation, damaged product and machinery, litigation
and insurance premiums, and training of staff.
How can safety reduce cost? A correctly designed and integrated machine safety system can
reduce cost in many ways, some not as obvious as others.
Simplifying system design by integrating standard and safety
control in one platform can help:
• Reduce installation and commissioning costs by utilising
common programming tools
• Simplify testing and troubleshooting
• Reduce costs associated with personnel training
as interface platforms can be standardised
• Reduce system complexity thus reducing
components needed
Utilise contemporary safety techniques such as zone control,
muting, and safe-speed control to achieve optimum machine
operation and flexibility when carrying out:
• Part loading and unloading
• Maintenance tasks under partial power
• Operational interaction
Simplifying hardware and software needed:
• Single network for automation and safety control
• Single programming environment
• Embedded safety functions into automation
products such as controllers, drives, motion,
and network technologies
And a key method to reduce cost is to apply the correct level of
safety needed:
• Assess the level of safety that is appropriate for your
application through risk assessment
• Selecting a supplier that offers the 3 parts of a safety system
(input, Logic and actuator) will allow you to choose the level of
safety you need, not the level they have to offer. Many safety
solution providers are unable to provide a total safety solution
and generally do not have an automation background
• A single vendor able to offer standard automation and safety
can help reduce its customer’s cost of vendor management
• Applying the appropriate level of safety can help minimise
nuisance trips thus reducing cost associated with waste and
lost production
“We’ve been using ControlLogix® andGuardPLC™ systems in other parts ofthe plant and have been quite happywith both.”
“The GuardLogix system combinesthese two into one, so we can sharedata tags and simplifyimplementation. It’s also much moremaintainable, since our maintenancestaff is already familiar with ControlLogix.”
Tracy Harvey
Senior Electrical Engineer, 3M Canada
9www.klinkmann.com6 / 2011
Improving capability
An integrated safety solution can help you attainand maintain the very highest levels of overallequipment effectiveness with minimal disruptionto your production line.
10
Contemporary safety technology can bring a wide range of
significant benefits; not merely providing a faster return on safety
investment, but positively contributing to productivity, too.
Helping you maximise efficiency
You always want to minimise downtime. But when it happens, you
want to be up and running as soon as possible. Safety systems with
improved diagnostics, which inform operators where faults have
occurred, can help reduce the time taken to get a machine back
online. Other solutions, such as zoning (slowing or stopping just
part of the machine) and safe torque off (avoid machine cycling
due to total power removal) can also help machine efficiency.
Rockwell Automation can advise on many ways in which safety can
contribute to Overall Equipment Effectiveness (OEE).
Making maintenance easierPredictive maintenance helps to minimise machine faults, but
they can still occur from time to time. With standard and safety
control systems integrated seamlessly within one platform,
utilising HMI displays through an open network, faults can be
more quickly identified and fixed, thus reducing your total repair
time. A single control environment for automation and safety
control can also simplify training for operation, maintenance and
troubleshooting efficiency.
Avoiding machine shutdownSometimes it’s desirable to maintain power when accessing
potentially hazardous areas for operations such as loading and
unloading. It is never advisable to bypass a safety system to achieve
this, but what’s the alternative if a safety system is implemented in
an operationally restrictive manner? In fact, it is possible to utilise
alternative methods to LOTO (Lock-out – Tag-out) or total power
removal. With the correct application of a functional safety solution,
operational ability can be achieved safely and efficiently.
www.klinkmann.com6 / 2011
“The safety control system also initiatesa controlled shutdown if the web breaks,which happens from time to time,” Kellyadds. “In this case, the web is first ejected out the back of the folding machine toprevent it from becoming jammed andpotentially damaging the machine. It’salso much easier to start up again.”
Paul Kelly
General Manager, Shepparton NewspapersPrinting Division
Simplifying machine management When a machine is in service how do you know that it has not been
changed inadvertently? The solution is to implement a programme
to manage your safety system over its operational lifecycle. Such a
system will use security, change management and change
notification tools, so that you can be confident that the machine’s
safety system remains in its optimum state.
Improving overall machine effectivenessIntegrated safety solutions can also help improve Overall Equipment
Effectiveness (OEE). Defined as ‘Availability x Performance x Quality’,
OEE is a Best Practice metric for monitoring and improving the
efficiency of manufacturing processes (i.e. machines, cells, assembly
lines, continuous processing applications, etc). Integrated safety
solutions from Rockwell Automation can help you attain and
maintain a world-class OEE score by, for example, enabling
maintenance, repair or loading to occur with minimal disruption to
an active production line.
Publication: SAFETY-BR003B-EN-P - April 2009 Copyright ©2009 Rockwell Automation, Inc. All Rights Reserved. Printed in UK
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