practical benefit of risk assessment - automate show definition sources: 1) iso 12100-1:2010 2) ansi...

Mark NehrkornDirector RCC Safety

SICK Inc.

Practical Benefit of Risk Assessment:Zone Determination by Layout Analysis

What is a Zone?

• A zone may include space within or around the system:

• which is used by personnel to access a specific location, an operating position or a servicing point;

• in which personnel perform standard production operations or other tasks.

• zone: a segmented space within a machine

• control zone: An identified portion of a production system under coordinated control

• hazard zone: Any space within or around a machine in which a person can be exposed to a hazard in which an immediate or impending hazard exists

• task zone: Any predetermined space within or around a machine in which a person can perform work

Definition Sources: ISO11161:2007, ANSI B11.19-DRAFT #8, ANSI B11.20 – DRAFT #7

Types of Zones

• Automation systems should be designed to facilitate safe manual interventions

• For some manual interventions, it may be impractical to stop the whole system

• … in which case the system should be segregated into zone(s) where personnel can perform their tasks safely

Why Create Zones?

Operation MaintenanceSet-Up Troubleshooting

Where is Guidance Available?

• ANSI/RIA R15.06-2012, Part 2 (ISO 10218-2:2011)• 5.9 Integrated manufacturing system (IMS) interface

• 5.9.1 General

• 5.9.2 Emergency stop

• 5.9.3 Safety-related parts of the IMS

• 5.9.4 Local control

• 5.9.5 Enabling device

• 5.9.6 Mode selection

• 5.9.7 Task zone implementation

Where is Guidance Available?

• ISO 11161:2007 + Amd 1:2010• Safety of machinery — Integrated manufacturing

systems — Basic requirements

• ANSI B11.20-2004 (R2015)• Safety Requirements for Integrated Manufacturing

Systems

RISK ASSESSMENT

Interrelationship of Standards

ISO 10218-1 ANSI/RIA R15.06 (Part 1)

Integrated Manufacturing System(IMS)

Robotsystem/cell

Robot

Other machine(C-type) standard

ISO 12100

ISO 11161

ISO 10218-2 ANSI/RIA R15.06 (Part 2)

ANSI B11.20

RIA R15.306 & ANSI B11.0

• This figure describes the relationship of the scope of machinery standards used in a robot system

• The robot alone is covered by Part 1, the system and cell is covered by Part 2

• A robot cell may include other machines subject to their own C level standards, and the robot system can be part of an

integrated manufacturing system covered by ISO 11161 which in turn can also make reference to other relevant B and C

level standards

• Part 2 adds additional information in line with ISO 12100 and ISO 11161

Source: ANSI/RIA R15.06, Part 2, Figure 1

Interrelationship of Standards

Image Source: ANSI/RIA R15.06, Part 2, Annex B

Integrated Manufacturing Systems

• An integrated manufacturing system (IMS):a) incorporates two or more industrial machines which:

1) can operate independent of each other, and

2) are intended for the purpose of manufacturing, treatment, movement or packaging of discrete parts or assemblies;

b) is linked by a material handling system; and

c) is interconnected by a control system(s) for coordinated operation

(saw)

Die carrier

Platen

Butt shear

Gate lock cylinder

Span of Control

• span of control: Predetermined portion of the production system under control of a specific device

• The control of one or more control zones of the machine by various safety-related control devices is defined by the span of control of each device

Definition Source: ISO11161:2007, ANSI B11.19-DRAFT #8, ANSI B11.20 – DRAFT #7

Devices with Span of Control

• Typical safety-related control devices which may have span of control include:

• INPUT:

• OUTPUT:

• Safeguarding devices:

o Interlock devices

o Presence sensing devices

• Complimentary control devices:

o Emergency stops

o Enabling devices

o Hold-to-run controls

o Resets

• End switching devices:

o Contactors

o Valves

o Drives

Span of Control & Layout Analysis

• Additional guidance in future machine-specific (Type-C) ANSI standards:

• The span of control of safety-related control devices shall be determined by a layout analysis, which includes:

• Specification of the limits

• Task/hazard pairs as identified from a risk assessment

• Task zone identification

• Selecting risk reduction measures

• Control zone identification

Risk Assessment Process

Image Source: ANSI B11.0-2015, Figure 6 (Used with permission)

Referenced by RIA TR R15.306-2016, Clause 6

Layout Analysis Process

Image Source: ANSI B11.20-DRAFT #7

Comparison of Processes

Risk Assessment Process Layout Analysis Process

Combination of Processes

Applying Layout Analysis to an Example Risk Assessment

Risk Assessment Example

• Palletizing Cell


• Identification of Tasks

A

B A

B

CD

A: Load/Unload Pallets

B: Cleaning

C: Teaching Robot

D: Jam Clearing

E: Conveyor Maintenance

ED

F2

F1

F1

F2

F1

Definition Sources: 1) ISO 12100-1:2010 2) ANSI B11.0-2015

2) task: Any specific activity

that is done with, on or around

the machine during its lifecycle.

1) task: specific activity

performed by one or more

persons on, or in the vicinity of,

the machine during its life cycle


• Identification of Hazard SourcesF2

F1

F1

F2

F1

Definition Sources: ISO 12100-1:2015, ANSI B11.0-2015

12

1: Robot / End Effector

2: Conveyor Lifts

3: Conveyors

32

hazard: A potential source

of harm


• Identification of Hazard Types

Definition Sources: ISO 12100-1:2015, ANSI B11.0-2015


2: Conveyor Lifts

3: Conveyors

12

1a: Crushing

1b: Dropped parts

2a: Shearing

2b: Pinching

2c: Entanglement

3a: In-running nip points

32

S3

S1

S4

S2

S3

S2


2: Conveyor Lifts

3: Conveyors


• Identification of Task Zones

Definition Sources: ISO11161:2007, ANSI B11.19-DRAFT #8, ANSI B11.20 – DRAFT #6

task zone: Any predetermined

space within or around a machine

in which a person can perform work

IIIIII

I: Load/Unload & Cleaning

II: Teaching Robot

III: Jam Clearing

IV: Maintenance

IVIII

I


• Risk Assessment: Identify Task / Hazard Pairs

HA

ZAR

DS ROBOT CONVEYOR LIFTS CONV.

1a 1b 2a 2b 2c 3a

TASKS Crushing Dropped Parts Shearing Pinching Entang. In-Running Nips

A L/UL 1 2 - - - - F2

B Cleaning 3 4 - - - - F1

C Teaching 5 6 - - - - F1

D Clearing 7 8 9 10 11 12 F2

E Maint. 13 14 15 16 17 18 F1

S3 S1 S4 S2 S3 S2


• Risk Assessment: Risk Estimation

ID Task Haz-ard Sever-ityExp-

osureAvoid-ance

Occur-rence

Risk Level

PLr

1 A 1a S3 F2 A1 O2 4 d

2 A 1b S2 F2 A2 O2 1 b

3 B 1a S3 F1 A1 O1 1 b

4 B 1b S2 F1 A2 O1 0 a

5 C 1a S3 F1 A1 O3 3 c

6 C 1b S2 F1 A2 O1 0 a

7 D 1a S3 F2 A1 O1 3 c

8 D 1b S2 F2 A2 O1 0 a

9 D 2a S3 F2 A2 O2 6 d

10 D 2b S1 F2 A2 O2 0 a

11 D 2c S2 F2 A2 O2 1 b

12 D 3a S1 F2 A2 O2 0 a

13 E 1a S3 F1 A1 O1 1 b

14 E 1b S2 F1 A2 O1 0 a

15 E 2a S3 F1 A2 O2 3 c

16 E 2b S1 F1 A2 O2 0 a

17 E 2c S2 F1 A2 O1 0 a

18 E 3a S1 F1 A1 O2 0 a


• Control Zones for Coexistence

Co

ntr

ol Z

on

e ACo

ntr

ol Z

on

e B

Control Zone C


• Apply Protective Measures (Gap in the Fence)

Safe!

But not very efficient…


R

R

R R

R R


• Safety-Related Span of Control

Control Zone C

Co

ntr

ol Z

on

e ACo

ntr

ol Z

on

e B

R

R

R

R

RR

RR


• Risk Assessment: Risk Reduction MeasuresID Task Hazard Severity Exposure Avoidance OccurrenceRisk

LevelPLr

Risk Reduction Measures:Technical Protective Measures & Administrative Measures

1 A 1a S3 F2 A1 O2 4 d Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled by Area scanner

2 A 1b S2 F2 A2 O2 1 b Interlocked sliding door, Light curtain

3 B 1a S3 F1 A1 O1 1 b Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled by Area scanner

4 B 1b S2 F1 A2 O1 0 a Interlocked sliding door, Light curtain

5 C 1a S3 F1 A1 O3 3 c Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1)

6 C 1b S2 F1 A2 O1 0 a Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1)

7 D 1a S3 F2 A1 O1 3 cInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

8 D 1b S2 F2 A2 O1 0 a Interlocked hinged door, Infeed light curtain, Interlocked sliding door, Safe distance, Awareness signs

9 D 2a S3 F2 A2 O2 6 dInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

10 D 2b S1 F2 A2 O2 0 aInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

11 D 2c S2 F2 A2 O2 1 bInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

12 D 3a S1 F2 A2 O2 0 aInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

13 E 1a S3 F1 A1 O1 1 b Control of hazardous energy (lockout/tagout), Safe work procedures

14 E 1b S2 F1 A2 O1 0 a Control of hazardous energy (lockout/tagout), Safe work procedures

15 E 2a S3 F1 A2 O2 3 c Control of hazardous energy (lockout/tagout), Safe work procedures

16 E 2b S1 F1 A2 O2 0 a Control of hazardous energy (lockout/tagout), Safe work procedures

17 E 2c S2 F1 A2 O1 0 a Control of hazardous energy (lockout/tagout), Safe work procedures

18 E 3a S1 F1 A1 O2 0 a Control of hazardous energy (lockout/tagout), Safe work procedures


• Interaction Matrix (Performance Levels and Span of Control)SAFETY-RELATED COMPONENTS HIGHEST LEVEL OF SAFETY PERFORMANCE

FUNCTION DEVICE LOCATION ROBOT CONVEYOR LIFTS CONVEYORS

PR

OT

ECTI

VE

STO

P

Light Curtain Conveyor Entrance d d b

Door Interlocks Lift Doors d d b

Door Interlocks L/UL Doors d d b

Door Interlock Maintenance Door d d b

Light Curtains L/UL Stations d - -

Area Scanners L/UL Stations d - -

Position Switches Robot Primary Axes d - -

EMER

GEN

CY

STO

P

E-stop Pushbutton Conveyor Entrance b b b

E-stop Pushbuttons Lift Doors b b b

E-stop Pushbuttons L/UL Doors b b b

E-stop Pushbutton Maintenance Door b b b

E-stop Cable Pull Cell Interior b b b

RES

ET

Reset Pushbutton Conveyor Entrance d d a

Reset Pushbuttons Lift Doors d d a

Reset Pushbuttons L/UL Stations d d a

Reset Pushbutton Maintenance Door d d a

AU

XIL

IAR

Y Muting Sensors Conveyor Entrance d d b

Mute Override Conveyor Entrance d d b

Awareness Lights L/UL Stations d - -


• Risk Assessment: Risk Reduction MeasuresID TaskHaz-ard

RISKIN

PLrRisk Reduction Measures:

Technical Protective Measures & Administrative MeasuresSeverity

Exposure

Avoidance

Occurrence

RISK OUT

1 A 1a 4 d Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled by Area scanner S3 F1 A1 O1 1

2 A 1b 1 b Interlocked sliding door, Light curtain S2 F1 A2 O1 0

3 B 1a 1 b Interlocked sliding door, Light curtain, Awareness light, Reduced robot speed controlled by Area scanner S3 F1 A1 O1 1

4 B 1b 0 a Interlocked sliding door, Light curtain S2 F1 A1 O1 0

5 C 1a 3 c Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1) S3 F1 A1 O1 1

6 C 1b 0 a Teach pendant (with enabling device and emergency stop), Manual reduced speed (T1) S2 F1 A1 O1 0

7 D 1a 3 cInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

S3 F1 A1 O1 1

8 D 1b 0 a Interlocked hinged door, Infeed light curtain, Interlocked sliding door, Safe distance, Awareness signs S2 F1 A1 O1 0

9 D 2a 6 dInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

S3 F1 A1 O1 1

10 D 2b 0 aInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

S1 F1 A1 O1 0

11 D 2c 1 bInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

S2 F1 A1 O1 0

12 D 3a 0 aInterlocked hinged door, Infeed light curtain, Interlocked sliding door, Emergency stop cable pull, Safe distance, Awareness signs

S1 F1 A1 O1 0

13 E 1a 1 b Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0

14 E 1b 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0

15 E 2a 3 c Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0

16 E 2b 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0

17 E 2c 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0

18 E 3a 0 a Control of hazardous energy (lockout/tagout), Safe work procedures S1 F1 A1 O1 0

Review

1. The risk assessment process:

• is used to reduce risks

• is also used to more logically isolate / segregate various zones within complex automation systems

2. Involvement of design engineers (systems, controls, etc.) in the risk assessment process is important in order to achieve maximum safety and productivity

3. Other industrial safety standards can and should be used for additional guidance to maximize the results of a risk assessment

Risk Productivity

Process

Mark NehrkornDirector RCC Safety

SICK Inc.6900 West 110th St.

Minneapolis, MN

USA

Telephone: 952-941-6780

Email: [email protected]

www.sick.com/us/en/


practical benefit of risk assessment - automate show definition sources: 1) iso 12100-1:2010 2) ansi...

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