RAOTM 2018 T77 Improving Productivity using Contemporary ... › resources › ... · New Design...

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Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 1

RAOTM 2018 – T77 – Improving Productivity using

Contemporary Safety Designs

Rajendran A Menon

Product Manager – Safety, Sensing & Connectivity Business

FS Eng (TUV Rheinland , #4597/11, Machinery)

PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

Application Example – System Optimization of Tc

Application Examples – Configurable Designs

Emerging Design Philosophies

Functional Safety Life Cycle

Safety as a Core System Function

Advanced Safety Concepts

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t © 2010

Safety as a Core System Function

Safety continues to emerge as core system function

Value – Safety as a Key Differentiator:

Global Compliance

Common Designs

Reduced Costs

Increased Productivity –

Systematic MTTR Reduction

Improved Competitiveness

Reduced Floor Space and Direct Labor

Improved Ergonomics

PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 4Copyright © 2010 Rockwell Automation, Inc. All rights reserved. 4

Safety as a Core System Function…But How?

New Tools:

Emergence of Global Specifications – ISO, IEC Standard Machine Designs that are Globally Compliant

New Safety Technologies – Tools for Improved

Machine Performance

New Design approaches – Passive, Configurable and Lockable “Design-In” Safety for user-friendly machines

A Systematic Design Approach is Required.

These systems don’t just happen!

The Rigor of The Functional Safety Lifecycle – Safety

By Design

Safety is a “Way of Life”


Functional Safety Life Cycle

STEP 5MAINTAIN & IMPROVE

SAFETY SYSTEM

STEP 1RISK OR HAZARD

ASSESSMENT

STEP 4SAFETY SYSTEM INSTALLATION &

VALIDATION STEP 3SAFETY SYSTEM

DESIGN & VERIFICATION

STEP 2SAFETY SYSTEM

FUNCTIONALREQUIREMENTS

Functional SafetyLife Cycle

PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 6Copyright © 2010 Rockwell Automation, Inc. All rights reserved.6

Risk Assessment – The Foundation

Provides Safety Performance Level – Design Target

Creates the Foundation of the Safety System Functional Requirements, System Design and Validation Protocol.

Shows “Due Diligence” and Global Compliance (Ref. ISO 12100)

S1

S2

F2

F1

Performance

Level, PLr

a

b

P1

P2

e

c

d

P1

P2

P1

P2

P1

P2

F2

F1

S = SeverityF = Frequency or Duration of ExposureP = Avoidance Probability

Task/Hazard

Contribution to

Risk Reduction

Low

High

Steps Include: Identification of Cross-

Functional Team

Determination of Machinery

Limits & Functions

Identification of Tasks &

Associated Hazards

Risk Estimation & Evaluation

Risk Reduction and Mitigation

Documentation


Emerging Design Philosophies

Passive System Design

Ensures the easy way is the safe way

Configurable System Design

Ensures the necessary functionality to accommodate

complex and variable maintenance procedures – by

design.

Helps to limit exposure to hazards while removing the

need or incentive to bypass.

Lockable Safety Systems

ANSI Z244-1 Compliant

Systems that systematically reduce MTTR/downtime

Safety AND Productivity


Improved Productivity by Design: MTTR Reduction

RunningDown

Ma

ch

ine

Sto

ps

Ma

inte

na

nce

Arr

ive

s

Fa

ult Id

en

tifie

d

LO

TO

Re

pa

ir P

erf

orm

ed

Ma

ch

ine U

nlo

cked

Re

pa

ir T

este

d

Ma

ch

ine

ba

ck in

Au

to

Pro

du

ctio

n R

esu

me

s

MTTR = 12 minutes (avg.)

Running

Typical Downtime Event


Safety Application - Perimeter Guarding

Gate Entry Box

• OFF (AUTO)

• Tool Outputs ON, Transfer Motion OFF

• Tool Outputs ON, Transfer Motion ON

• OFF (AUTO)

• Outputs ON, Servos OFF

• Outputs ON, Servos ON

Robots

Tooling

Easy, Intuitive and Secure

Point of Entry Configurable Safety System

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Safety Application - Perimeter Guarding

Results:

No need to bypass the safety system - It is designed to safely

accommodate the maintenance and operating procedures.

Higher productivity - Safety system may be used in lieu of

LOTO ( Lockout/Tagout) for many routine maintenance and

setup procedures.

Improved MTTR, faster start-ups, highly standardized

approach System is PASSIVE – The Easy Way is the Safe Way.

System is Lockable

Reduction of injuries and associated costs.Engineered and Integrated Safety Systems


Improved Productivity: Safety System Design

If the safety system design meets target

safety level, and ANSI Z244-1 applies…

The safety system may be used in lieu

of LOTO, reducing MTTR by ~2

minutes.

Manufacturer’s value of 1 minute

of production = $10K

Average downtime events

per plant per year = 3000 (8/day)Safety = Productivity = Profitability

$10K X 2min X 3000 =

$60M/yr.

Value of safety solution due to improved

productivity (reduced MTTR)


Safety System Optimization – What? Why? How?

What? - Safety System Optimization

Reduction of Safety Control System Latencies.

Simplification and Standardization of Safety Functions

Why? - Provides Manufacturing Systems that:

Reduce Staffing Requirements, Reduction in Direct Labor via Improved Labor

Efficiencies

Reduction of System Floorspace/Footprint

Reduction of Machine Cycle Times, Improved Productivity

Improved Ergonomics and Reduced Operator Strain

Ok – sounds good but….HOW???

Optimized Safety Systems can Reduce Costs!


Safety System Optimization – Safe Distance

Optimization of Tc

Safe Distance Calculation is Ds = K(Tr + Ts + Tc) + Dpf

Systematic Reduction of safety control system latencies

Method 1 - Local processing – Safety “Chicken Brains”

Method 2 - Network scheduling RPI and safety task interval

Method 3 – Combination with Hardwired Systems

Improves: Operator Utilization, Floorspace utilization, Ergonomics

Goal is to Architect Faster System Response


Safety System Optimization – Safe Distance

Table 6 from ANSI/RIA 15.06


t © 2009

Safety System Optimization - Example

Valve

bank

Tool or

FixtureOperator


t © 2009


Valve

bank

Tool or

FixtureOperator

Motion Causing

Output Power


t © 2009


Valve

bank

Tool or

FixtureOperator

Motion Causing

Output Power

SIO SIO SIO

GLx


t © 2009


Valve

bank

Tool or

FixtureOperator

Motion Causing

Output Power

Tc = RPI + GLx Scan + RPI

= 50ms + 20ms + 50ms

= 120ms

.

.

.

SIO SIO SIO

GLx

Ref: Ds = K(Tr + Ts + Tc) + Dpf


t © 2009


Valve

bank

Tool or

FixtureOperator

Motion Causing

Output Power

SG600 SIO

GuardLogix

Tc = SG600 Scan

= 20ms (or less!)

Over 6” Ds Reduced!



t © 2009

Solution Value

Reduced System Floorspace

6” reduction X 4’ load window width = 2 sq ft per load window reduced

2 sq ft X 150 load windown/shop = 300 sq ft/shop reduced floorspace

300 sq ft X $100/sq ft/yr = $30K/yr savings (not incredible…)

Improved Operator Utilization

Typical Operator Cycle Break LC and move to load point 1.5 sec

Load Parts 5.0 sec

Exit load window 1.5 sec

Palm/Initiate Cycle 1.0 sec

Total = 9.0 sec

Our 6” Ds savings may reduce this operator cycle by 0.5 sec overall; 0.5/9=5.6%

If designed in, this may reduce direct labor by 5 headcount (100 person shop reduced 5%)

5 direct labor X $100K/head/yr (burdened) = $500K/yr reduced labor costs

Improved Ergonomics?Cost Savings can be Significant


t © 2009

Safety System Optimization – Other Approaches

How else could Tc be improved?

RPI’s configured to the application requirements

Hardwired approach

How could Ds be improved?


Can we affect Tr or Ts?

What about Dpf?

Safety System Optimization Requires a Systematic Approach


t © 2009

Safety System Optimization – New Thinking

Safe Motor Control – Controlling the Hazard

Typically either “On” or “Off” today – Contactors.

Safe Off, Safe Speed available today – Safe direction, position coming.

For Maintenance personnel, Operators

Changing the way hazards are managed Modulating hazards based upon human proximity vs shutdown.

Human Detection Methodology

Old Way – Simple “Go” or “No Go”

New Way – Multiple stage Detection with “Layers”

New Safety Technologies will Change the way Hazards are Managed

MSR-57


t © 2009

Safety System Optimization – New Thinking

Safe Motor Control – Safe Speed

Modulate Hazard rather than shut down

What does this do for Safe Distance

Calculation Ds? Ds = K(Tr + Ts + Tc) + Dpf

Decreased cell size, Improved Uptime,

reduced ergonomic load

Safe Zero Speed or “Standstill” for Operator Load

Energy Conservation

Load Work

MSR-57


Competitive and Safe Machines

Provides improved Machine Uptime & Ergonomics

Modulates Hazard rather than shutting down

Reduces Walk Distances

Can help remove incentive to bypass the Safety System

System is operator and maintenance friendly

New Safety Technologies enable these advanced

Safety Functions

Improved Safety AND Improved Productivity!

Load Work

MSR-57

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