Safety by Design: Soft Guarding

Safety by DesignSafety by Design

Presented by Jeff Winter

Safety By DesignWho is Omron STI?Who is Omron STI?Why Safeguard? Wh t l l d l ti th ?What rules, laws, and regulations are there?Where and how do I start?What products can help?

About Omron STI

We are Omron’s Global Safety Brand

Safety Market Leader in Safety Market Leader in North America

266 Employees 55 Engineers 55 Engineers Omron added Production

Capacity from Japan to Fremont for North American market

Headquarters & Manufacturing95,700 sq. ft.

Omron STI Provides both Products and Services

30 + years of experience in providing unbiased safety solutions custom designed for yoursafety solutions custom designed for your particular application

Large product selectiong pSafety integration servicesGlobal support networkGlobal support network


Why do we need toWhy do we need to be Safe?

Why Should you Safeguard?Why Should you Safeguard?Besides the ObviousBesides the Obvious……

There are MANY hidden costs:Compliance FinesWorker’s CompInsurance IncreasesDowntimeLost Productivity

Safety Productivity


What does the Law Say?Do your customers NEED to

Safeguard?Safeguard?

What does the law say about OEMs?

Do I need to apply safety to the machines I am building?am building?

The correct answers isThe correct answers is.......

I D dIt Depends…..

What does it depend on?

1. Where is the machine going?

2 What are the customer’s requests?2. What are the customer s requests?

Is an ANSI standard the same thing as an OSHA standard or law?OSHA standard or law?

Are you required to follow it?Are you required to follow it?

What happens if you don’t?What happens if you don t?

What is Product Liability? The responsibility of a manufacturer or vendor of goods to The responsibility of a manufacturer or vendor of goods to

compensate for injury caused by defective merchandise that it has provided for sale.

When individuals are harmed by an unsafe product they may When individuals are harmed by an unsafe product, they may have a Cause of Action against the persons who designed, manufactured, sold, or furnished that product In most jurisdictions a plaintiff's cause of action may be In most jurisdictions, a plaintiff s cause of action may be

based on one or more of four different theories: Negligence, breach of Warranty, Misrepresentation, and strict tort liability.

i f f f i iNegligence refers to the absence of, or failure to exercise, proper or ordinary care. It means that an individual who had a legal obligation either omitted to do what should have been g gdone or did something that should not have been done.

A new national policy was established on December 29, 1970, when President Richard Nixon signed into law the OSHActNixon signed into law the OSHAct

For employers, the General Duty clause is used by OSHA when there are NO specificused by OSHA when there are NO specific standards applicable to a hazard.

OSHA's purpose is to save lives, prevent workplace injuries and illnesses, and protect the health of all America's workers.

Every year: over 6,000 Americans die from workplace injuries anestimated 50,000 people die from illnesses

caused by workplace chemical exposurescaused by workplace chemical exposures 6 million people suffer non-fatal workplace injuries

Injuries alone cost the economy more than $110 billion a year.

THE LAWTHE LAW

Part 24:Part 70:Part 70A: Part 1903:Part 70:Part 70A:Part 24:Part 1910:Part 70A:Part 70A:Part 24:Part 70:Part 70A:Part 70A:Part 24:Part 70:Part 24:Procedures for the Handling of

Retaliation Complains

Part 70:Production or Disclosure of Information or

Materials

Part 70A:Protection of

Individual Privacy in Records

Part 1900:Reserved

Part 1901:Procedures for

State Agreements

Part 1902:State Plans for the Development and

Enforcement of State Standards

Part 1903:Inspection,

Citations, and Proposed Penalties


Materials



Part 24:Procedures for the Handling of


Part 1910:Occupational Safety and

Health Standards








Materials








Materials

Part 1919:Gear

CertificationComplainsMaterialsRecords PenaltiesMaterialsRecordsComplainsStandardsRecordsRecordsComplainsMaterialsRecordsRecordsComplainsMaterials


Retaliation



Individual Privacy in


Retaliation





Retaliation





Retaliation







Retaliation







Retaliation


Part 2400:Regulations

Implementing Retaliation Complains

Information or Materials

Privacy in Records



Privacy in Records



Privacy in Records



Privacy in Records

Privacy in Records



Privacy in Records

Privacy in Records



p gthe Privacy Act

THE LAWTHE LAW

Part 1910:Occupational p

Safety and Health Standards

S b t A S b t H S b t O S b t VSubpart A: General

Subpart B: Adoption and Extension of Established Federal StandardsSubpart C: Adoption

d E t i f

Subpart H: Hazardous MaterialsSubpart I: Personal Protective EquipmentSubpart J: General E i t l C t l

Subpart O: Machinery and Machine GuardingSubpart P: Hand and Portable Powered ToolsSubpart Q: Welding, C tti d B i

Subpart V: Reserved

Subpart W: Reserved

Subpart X: ReservedStandardsand Extension of Established Federal StandardsSubpart D: Walking-Working SurfacesSubpart C: Means of EgressSubpart F: Powered

Environmental ControlsSubpart K: Medical and First AidSubpart L: Fire ProtectionSubpart M:

Cutting, and BrazingSubpart R: Special IndustriesSubpart S: Electrical

Subpart T: Commercial

Subpart Y: Reserved

Subpart Z: Toxic and Hazardous Substances

Subpart F: Powered Platforms, Manlifts, and Work PlatformsSubpart G:Occupational Health and Environment

pCompressed Gas and Compressed Air EquipmentSubpart N: Materials Handling and Storage

pDiving OperationsSubpart U: Reserved

1910.211-1910.219

1910.211: Definitions

1910.212: General Requirements for all Machinery Point of Operation is Defined

1910.213: Woodworking machinery requirements

1910.214: Cooperage Machinery - Reserved

All cracked saws shall be removed from service.

Subpart O: Machinery and Machine Guarding

1910.215: Abrasive Wheel Machinery

1910.216: Mills and Calenders in the rubber and plastics industries

All abrasive wheels shall be mounted between flanges which shall not be less than one-third

the diameter of the wheel.

All trip and emergency switches shall not be of the automatically resetting type, but shall and plastics industries

1910.217: Mechanical Power Presses

1910 216: Forging Machines

require manual resetting.

A pad with a nonslip contact area shall be firmly attached to the pedal.

1910.216: Forging Machines

1910.216: Mechanical power-transmission apparatus

For those hard of seeing:$63,359,935JUST manufacturing$63,359,935

General Overview

1910.212 (a)(1):One or more methods of machine guarding shall be provided

to protect the operator and other employees in the machine p p p yarea from hazards such as those created by point of operation, ingoing nip points, rotating parts, flying chips, and sparks.

1910.212(a)(3):The guarding device shall be in conformity with any The guarding device shall be in conformity with any

appropriate standards therefor, or, appropriate standards therefor, or, in the absence of in the absence of applicable specific standardsapplicable specific standards shall be so designed andshall be so designed andapplicable specific standardsapplicable specific standards, shall be so designed and , shall be so designed and constructed as to prevent the operator from having any part constructed as to prevent the operator from having any part of his body in the danger zone during the operating cycle.”of his body in the danger zone during the operating cycle.”

What happens if I don’t What happens if I don t follow?

Seriousup to $7000 per violation

Other than Seriousdiscretionary but not more than $7000discretionary but not more than $7000

Repeatup to $70,000 per violation

Willfulup to $70,000 per violationViolations resulting in death- further penaltiesg p

Failure to abate$7000/day

The problem with OSHA….

Open for interpretation….

Find X.

3cmX

44cm

How do you PROVE you are Safe?

ANSI NFPA RIA ULANSI NFPA RIA UL

Follow a recognized standard toFollow a recognized standard to demonstrate your compliance

ANSI Standards

American National Standards Institute (ANSI) are voluntary standards developed by experts in the ind strindustry.

ANSI standards are detailed, technical ,documents that provide rules, guidelines or characteristics for a product or process.

ANSI standards explain the hazards involved in operating machinery

Voluntary Standards & The General Voluntary Standards & The General Duty Clause

A ANSI t d d i t l b t b

OSHA standards typical establish the general standards employers must

If OSHA determines that compliance with the voluntary standard would have prevented or

lessened the severity of an injury, OSHA may cite th l ’ f il t f ll th t d d An ANSI standard is not a law, but can become

mandatory! This happens through a process called “incorporation

g p ymeet without specifying how. OSHA

gives the employer discretion to decide how best to achieve the standard’s

goals But OSHA ( and the courts ) do

the employer’s failure to follow the standard as a violation of the general duty clause.

This happens through a process called incorporation through reference” when an OSHA standard cites a specific ANSI standard.

You can be cited for not following voluntary

goals. But OSHA ( and the courts ) do say how they EXPECT employers to use the discretion provided by the

standard You can be cited for not following voluntary

standards!OSHA may cite you for not following a standard like NFPA

70E even though it is not incorporated into OSHA.

ANSI B11 Safety StandardsAMT EHS - Environmental Health and SafetyANSI B11 ASC - Accredited Standards CommitteeANSI B11.1 - Mechanical Power PressesANSI B11 2 H dra lic Po er Presses

ANSI B11.22 - Turning MachinesANSI B11.23 - Milling, Drilling and Boring MachinesANSI B11.24 - Safety Requirements for Transfer MachinesANSI B11.TR1-2004 - Ergonomic Guidelines

y

ANSI B11.2 - Hydraulic Power PressesANSI B11.3 - Mechanical Power Press BrakesANSI B11.4 - ShearsANSI B11.5 - IronworkersANSI B11.6 - LathesANSI B11.7 - Cold Headers and Cold Formers

ANSI B11.TR1 2004 Ergonomic Guidelines ANSI B11.TR2-1997 - Mist Control Considerations ANSI B11.TR3-2000 - Risk Assessment and Risk ReductionANSI B11.TR4-2004 - Selection of PES/PLC) for Machine ToolsANSI B11.TR5-2006 - Sound Level Measurement GuidelineANSI B11.TR6-200X - Control Reliable CircuitsANSI B11.7 Cold Headers and Cold Formers

ANSI B11.8 - Drilling, Milling, and Boring MachinesANSI B11.9 - Grinding MachinesANSI B11.10 - Sawing MachinesANSI B11.11 - Gear and Spline Cutting MachinesANSI B11.12 - Roll-Forming and Roll-Bending Machines

ANSI B11.TR7-2007 - Lean Manufacturing ANSI B15.1-2000 - Mechanical Power Transmission ApparatusANSI B65.1-2005 - Printing Press SystemsANSI B65.2-2005 - Binding and Finishing SystemsANSI B65.3-2001 - Guillotine Paper Cutters, Mill Trimmers ANSI B65 4 2002 Three Knife TrimmersANSI B11.13 - Chucking Machines

ANSI B11.14 - Coil Slitting MachinesANSI B11.15 - Pipe, Tube, and Shape Bending MachinesANSI B11.16 - Powder/Metal Compacting PressesANSI B11.17 - Horizontal Hydraulic Extrusion PressesANSI B11 18 Plate From Coiled Configuration

ANSI B65.4-2002 - Three-Knife TrimmersANSI B65.5-2006 - Stand-Alone Platen PressesANSI B151.27 - Plastics Machinery Robots ANSI B155.1-2006 - Packaging MachineryANSI B56.5 - Industrial VehiclesANSI/ASSE Z244.1 - Control of Hazardous EnergyANSI B11.18 - Plate From Coiled Configuration

ANSI B11.19 - Performance Criteria for SafeguardingANSI B11.20 - Integrated Manufacturing SystemsANSI B11.21 - Lasers for Processing Materials

gyANSI/RIA R15.06 - Industrial Robots and Robot SystemsANSI/RIA TR R15.106 - Teaching Multiple RobotsANSI/RIA TR R15.206 -Guidelines for Implementing


S Wh h ld I d f dSo………What should I do to safeguard my machine?

ANSWER:

Review Applicable Standards and Conduct an Assessment

What is it?

Risk AssessmentThe process by which the intended use of theThe process by which the intended use of the

machine, the tasks and hazards, and the level of risk are determined

Risk ReductionThe application of protective measures to

reduce the risk to a tolerable level

Why do a risk assessment?Why do a risk assessment? To create a safer working environment for employees (as required by

OSHA)

To reduce costs

To comply with national and international consensus standards, including:ANSI B11.TR3-2000 – Risk Assessment and Risk Reduction – A Guide to Estimate,

Evaluate and Reduce Risks Associated with Machine ToolsEvaluate and Reduce Risks Associated with Machine ToolsANSI/RIA R15.06-1999 – For Industrial Robots and Robot Systems – Safety

RequirementsANSI/NFPA 79-2007 – Electrical Standard for Industrial MachineryANSI/ASSE Z244.1-2003 – Control of Hazardous Energy – Lockout/Tagout and

Alternative MethodsAlternative MethodsANSI/PMMI B155.1-2006 – Standard for Packaging Machinery and Packaging-Related

Converting Machinery – Safety Requirements for Construction, Care, and UseCSA Z432-04 – Safeguarding of Machinery – Occupational Health and SafetyCSA Z434-03 – Industrial Robots and Robot Systems – General Safety RequirementsCSA Z460-05 – Control of Hazardous Energy – Lockout and Other MethodsEN 1050:1996 / ISO 14121:1999 – Safety of machinery – Principles of risk assessmentEN 954-1:2000 / ISO 13849-1:1999 – Safety of machinery – Safety-related parts of control

systems – Part 1: General principles of designISO 12100-1:2003 – Safety of machinery – Basic Concepts, general principles for design –

Part 1: Basic terminology, methodologyISO 12100-2:2003 – Safety of machinery – Basic Concepts, general principles for design –

Part 2: Technical principles

How do I do it?Pick a standard to folloPick a standard to followANSI, CSA, ISO

Y t lYou can create your own process, as long as it’s based on industry best practices

You can conduct the process in houseYou can conduct the process in house, request it from your OEM, or contract an outside service provideroutside service provider

Risk Assessment MatrixRisk Assessment Matrixfrom ANSI/RIA R15.06-1999

Table 2Table 2Avoidance Risk Reduction Category

A2 Not Likely R1Severity of Exposure

S2 S i I j

ExposureE2 Frequent A2 Not Likely R1

A1 Likely R2AA2 Not Likely R2BA1 Likely R2B

S2 Serious Injury More than First-aid

E2 Frequent Exposure

E1 Infrequent Exposure A1 Likely R2B

A2 Not Likely R2CA1 Likely R3AS1 Slight Injury

ExposureE2 Frequent

ExposureA2 Not Likely R3BA1 Likely R4

E1 Infrequent Exposure

First-aid

Table 2 - Risk reduction decision matrix prior to safeguard selectionp g

Risk Reduction MeasuresRisk Reduction Measuresfrom ANSI/RIA R15.06-1999

Table 3Table 3Category Circuit Performance

Control Reliable (4.5.4)R1

Hazard Elimination or hazard substitution (9.5.1)

SafeGuard Performance

Control Reliable (4.5.4)

Single Channel with monitoring (4.5.3)

R2A

R2B

Engineering controls preventing acess to the hazard, or stopping the hazard (9.5.2), e.g. interlocked barrier guards, light curtains safety mats or other presence

Non interlocked barriers, clearance,

Single Channel (4.5.2)

Single Channel (4.5.2)

R2C

R3A

curtains, safety mats, or other presence sensing devices (10.4)

, ,procedures and equipment (9.5.3)

Awareness means (9.5.4)R4

Simple (4.5.1)

Simple (4.5.1)

R3A

R3B

Table 3 - Safeguard Selection MatrixR4

If there are Hazards, there MUST be Risk ReductionReduction

PROTECTIVE MEASURE EXAMPLES

Most EffectiveElimination or Substitution

Eliminate human interaction in the processEliminate pinch points (increase clearance)

This can only be done by the OEMElimination or Substitution Eliminate pinch points (increase clearance)

Automated material handling (robots, conveyors, etc.)

Engineering Controls(Safeguarding Technology /

BarriersInterlocksPresence sensing devices (light curtains, safety mats, area scanners, etc.)

done by the OEM

Protective Devices) Two hand control and two hand trip devices

Awareness Means Lights, beacons, and strobesComputer warningsSigns and labelsBeepers, horns, and sirens

So what is the difference between These 3 rely Beepers, horns, and sirens

Training and Procedures(Administrative Controls)

Safe work proceduresSafety equipment inspectionsTrainingLockout / Tagout / Tryout

these 3 sections?y

on human behavior!

Least Effective

Personal Protective Equipment(PPE)

Safety glasses and face shieldsEar plugsGlovesProtective footwearRespirators

Hierarchy of Control

If there are Hazards, there MUST be Risk ReductionReduction

PROTECTIVE MEASURE EXAMPLES

Most EffectiveElimination or Substitution

Eliminate human interaction in the processEliminate pinch points (increase clearance)Elimination or Substitution Eliminate pinch points (increase clearance)Automated material handling (robots, conveyors, etc.)

Engineering Controls(Safeguarding Technology /

BarriersInterlocksPresence sensing devices (light curtains, safety mats, area scanners, etc.)

Protective Devices) Two hand control and two hand trip devices

Awareness Means Lights, beacons, and strobesComputer warningsSigns and labelsBeepers, horns, and sirensBeepers, horns, and sirens

Training and Procedures(Administrative Controls)

Safe work proceduresSafety equipment inspectionsTrainingLockout / Tagout / Tryout

Least Effective

Personal Protective Equipment(PPE)

Safety glasses and face shieldsEar plugsGlovesProtective footwearRespirators

Hierarchy of Control

What do you think the number of machines we conducted 10 000 machines we conducted 10,000

Risk Assessments on were guarded correctly?guarded correctly?

7%7%7%7%

Their current guards proved to be a waste of time and money when done incorrectly!

If You don’t………..

What are Hazards on a Machine or Process?

• Physical• Falling / Moving Objects

• ElectricalFl h d B• Falling / Moving Objects

• Collisions• Collapsing Structures

• Flashover and Burns• Electrocution• Wrong Connection / Loose Connection

• Mechanical / Process• Pinch Points or Entanglement• Abrasion Grinding Cutting

• Chemical• Explosion• Fire Abrasion, Grinding, Cutting

• Thermal• Pressure Releasing Effects (Bursting Vessels,

Jets of Gas or Liquids)

Fire• Toxic Material Release• Wrong mix of chemicals• Radiation Jets of Gas or Liquids)

• Welding Torches, Gases etc.• Radiation

Hazards are physical objects or chemical substances that have the t ti l f i h t l t th i tpotential for causing harm to people, property or the environment

What methods for machine safety

Location/distance Guards

are there?

Feeding and ejection methods automatic and/or semi-

fixed interlocked adjustable automatic and/or semi

automatic feed and ejection

robots

adjustable self-adjusting

Devices robots

Miscellaneous aids awareness barriers

Devices presence sensing pullback

awareness barriers protective shields hand-feeding tools

restraint safety controls (tripwire cable,

two-hand control, etc.) gates



are there?




robots


Devices robots








are there?




robots


Devices robots






Safety Distance Formula

From ANSI/RIA R15.06-1999 Annex B

Otherwise……

Safe Mounting Distance FormulaTotal

D K(T ) + DStopping

Time

Ds = K(Ts) + Dpf

Safe M ti

Hand Speed Depth

P t tiMounting Distance

Constant63 inc/sec

PenetrationFactor


Products used to safeguardProducts used to safeguard

MS4800 T BMS4800 – Two BoxAll models can beAll models can be

cascadedCascade up to 4 p

segments (256 beams max)

Key features: IBI’s – easy to align, diagnostics

F3SJ – Two BoxYou pick the resolutionYou pick the resolutionYou pick the heightCascadableCascadableKey features: Sophisticated

muting single beam bimuting – single beam, bi-directional, outputs can be modified via offline editor

Light Curtain Accessories

EP Enclosures available for protected heights of 10” to 48”48

IP67 enclosures - 10” to 82”

Interlock Switches: Three Basic Interlock Switches: Three Basic Categories

Traditional mechanical switchNon ContactNon ContactSolenoid-lockingD I d it i l ?Do I need a monitoring relay?

D4NS Compact Plastic Door D4NS Compact Plastic Door Switch

O ti l t l Optional metal operation head

9 different conduit 9 different conduit entrances / M12 connector

6 different internal switch configurations Up to 3 contactsp

Key feature: 20% -30% lower price than

OSTI b dnon-OSTI brands

D4GL Keyed Solenoid Door D4GL Keyed Solenoid Door Switch

Si il t D4NL Similar to new D4NL, features “in-line” construction

t 3 t f f t up to 3 sets of safety contacts and 2 solenoid monitoring contacts

k h ldi f f 1000N key holding force of 1000N metal operation head Key feature: 20% - 30%

lower price than non-OSTI brands

D4GL-SK10-LKAA-43

Solenoid locking switch and integral slide bolt

LEDs for open/close/locked Integral lock-out keyUp to 5 contactsPower to lock or power to

unlock 24 Vdc onlyNo rear release

D40A/G9SX-NSCompact Non-Contact Door Switch/

Flexible Safety UnitFlexible Safety Unit

Advantage over Magnetic Switches

Competitor’s 6 units max (w/LED)(w/LED)

D40A (Up to 30 units w/LED )D40A-(Up to 30 units w/LED )

Advantage over Magnetic Switches

On machines with a lot of doors,it is difficult to know

hi h d i dwhich door is opened.Solution

Even half-opened door is indicated byAuxiliary output

＋－Yellow line is Auxiliary output

SignalSignal

Yellow line is Auxiliary output

Safety MatsSafety Mats UMQ Quick

Disconnect now available

Send us your Send us your drawings to ensure proper di idimensions

Key features –durable, easy todurable, easy to configure

You give us this

We give you this

OS3101: New and Improved

Key features:Very easy to programy y p g LED sector indicatorsDiagnostic displayg p yNow has multiple zones

OptoShield Operating PrincipleD = (c x T)/2

Distance to object determined by the “time of flight” of the light pulse.

OptoShield Operating PrinciplePulses sent out in 180o

Screen LayoutMenu Bar

Screen Layout

Tool Bar

Info Bar Warning Zone Safety Zone

NE1A Programmable Safety Modern network safety technologyNE1A Programmable Safety Controller

Modern network safety technology makes it possible to instantly safety-

stop a machine, easily segment an Intelligent Safety Network

Controller 1. Safety Logic functionality 2. DeviceNet Safety Master Functionality

application into safety zones or quickly diagnose a safety device

3. DeviceNet Slave Functionality 4. Local safety I/O

Easy Programming Safety based function Block Program Size: Max 128 Function Blocks Program Size: Max 128 Function Blocks Logic Editor contained within Configuration

Software

Local Safety and Slave I/O Password Security Password Security USB Port for Programming Global Safety Standards

2) Through the Logic Program) g g g

FAULT!

Questions?

Safety by Design: Soft Guarding

Technology

privacy information

safety productivity

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occupational production

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engineers omron

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product liability