How to safeguard your machines (Omron STI) Drive for Technology 2010 presentation

1. Safety by Design
Presented by Jeff Winter

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

3. About Omron STI
 We are Omron’s Global
Safety Brand
 Safety Market Leader in
North America
 266 Employees
 55 Engineers
 Omron added Production
Capacity from Japan to
Fremont for North
American market
Headquarters & Manufacturing
95,700 sq. ft.

4. Omron STI Provides both
Products and Services
 30 + years of experience in providing unbiased
safety solutions custom designed for your
particular application
 Large p
g product selection
 Safety integration services
 Global support network

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

6. Why do we need to
be Safe?

14. Why Should you Safeguard?
Besides the Obvious……
Obvious
 There are MANY hidden costs:
Compliance Fines
Worker’s Comp
Insurance Increases
Downtime
Lost Productivity

15. Safety Productivity

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

17. What does the Law Say?
Do your customers NEED to
Safeguard?

18. What does the law say about
OEMs?
 Do I need to apply safety to the machines I
am building?
 The correct answers is
is.......
It Depends…..
I D d

19. What does it depend on?
1. Where is the machine going?
2.
2 What are the customer’s requests?
customer s

20.  Is an ANSI standard the same thing as an
OSHA standard or law?
 Are you required to follow it?
 What happens if you don’t?
don t?

21. What is Product Liability?
 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
product,
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
jurisdictions plaintiff s
based on one or more of four different theories: Negligence,
breach of Warranty, Misrepresentation, and strict tort liability.
Negligence refers to the absence of, or failure to exercise,
 i f f f i i
proper or ordinary care. It means that an individual who had
a legal obligation either omitted to do what should have been
g g
done or did something that should not have been done.

22.  A new national policy was established on
December 29, 1970, when President Richard
Nixon signed into law the OSHAct
 For employers, the General Duty clause is
used by OSHA when there are NO specific
standards applicable to a hazard.

23.  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
 an estimated 50,000 people die from illnesses
caused by workplace chemical exposures
 6 million people suffer non-fatal workplace injuries
 Injuries alone cost the economy more than $110
billion a year.

24. THE LAW
Part 24: 70: 70A: Part Part 70: 70A: Part 70A: Part 70: 70A: Part 70:
PartPart 1903: Part 24: PartPart 24: PartPart 24:
Part Part 1910: 70A: Part 70A:
Part 1901:
Part 1902:
Procedures for or State Plans for theProceduresProtection of Protection of for or
Production
Protection of Inspection, Occupational Production or Production
Production or Protection of Protection of Part 1919:
Protection of for
Procedures forProcedures
Part 1900: for
Procedures
the Handling of of Development andIndividual Individual
Disclosure
Individual Citations, and Handlingand Handling of of Handling of of
Disclosure of
the Safety Individual Individual
of Disclosure
the Individual Gear
the Disclosure
State of State
Reserved
Information Enforcement
Retaliation or in
Privacy Proposed RetaliationPrivacy in Privacy in in
Information or in Privacy in
Privacy Health Retaliation Privacy Certification
Information or Information or
Retaliation
Agreements
Standards
Complains
Materials
Records Penalties Complains Records Records Materials
Materials StandardsComplains Records
Records Records Materials Complains
Part 24: 70: 70A: PartPart 24: 70: 70A: Part 70A: Part 70: 70A: Part 70:
Part Part 24: 70: 70A: PartPart 24: 70: Part 24: PartPart 24:
Part Part Part Part Part 70A: Part 70A:
Part 2400:
Procedures for Production Production Production or Production or Production or
Production or of Procedures for or of Protection of Protection of for
Protection Protection of Procedures forProcedures forProcedures
Procedures for or Protection Protection of Protection of
Regulations
the Handling ofHandling ofHandling ofHandling of of Handling of of Handling of of
Disclosure Disclosure Disclosure Disclosure
Individual Individual Individual Individual
the of the of the of Individual Individual
the DisclosureIndividual
the Disclosure
p
Implementing g
Retaliation Retaliation Retaliation Retaliation Privacy in Privacy in in
InformationInformationInformationInformation or in
Privacy in Privacy in Privacy in Privacy Information or Information or
or or or Retaliation Privacy
Retaliation
the Privacy Act
Complains Complains Complains Complains Records Records Materials
Materials Materials Materials Materials Complains Records
Records Records Records Records Materials Complains

25. THE LAW
Part 1910:
p
Occupational
Safety and Health
Standards
Subpart A: General
S b tA Subpart H: Hazardous
S b tH Subpart O: Machinery
S b tO Subpart V: Reserved
S b tV
Materials and Machine Guarding
Subpart B: Adoption Subpart I: Personal Subpart P: Hand and Subpart W: Reserved
and Extension of Protective Equipment Portable Powered Tools
Subpart C: Adoption
Established Federal Subpart J: General Subpart Q: Welding, Subpart X: Reserved
Standards i of
and E t
d Extension f Environmental C t l
E i t l Controls Cutting, and B i
C tti d Brazing
Subpart D: Walking-
Established Federal Subpart K: Medical and Subpart R: Special Subpart Y: Reserved
Standards
Working Surfaces First Aid Industries
Subpart C: Means of Subpart L: Fire Subpart S: Electrical Subpart Z: Toxic and
Egress Protection Hazardous Substances
Subpart F: Powered Subpart M:
p Subpart T: Commercial
p
Compressed Gas and Diving Operations
Platforms, Manlifts, and
Subpart G:
Work Platforms Subpart N:Air
Compressed Materials Subpart U: Reserved
Occupational Health and Equipment Storage
Handling and
Environment

26. 1910.211-1910.219
1910.211: Definitions
1910.212: General Requirements for all Machinery Point of Operation is Defined
All cracked saws shall be removed from service.
1910.213: Woodworking machinery requirements
1910.214: Cooperage Machinery - Reserved
All abrasive wheels shall be mounted between
flanges which shall not be less than one-third
1910.215: Abrasive Wheel Machinery Subpart O: Machinery
the diameter of the wheel.
and Machine Guarding emergency switches shall not be of
All trip and
1910.216: Mills and Calenders in the rubber
the automatically resetting type, but shall
and plastics industries
require manual resetting.
1910.217: Mechanical Power Presses A pad with a nonslip contact area shall be firmly
attached to the pedal.
1910.216:
1910 216: Forging Machines
1910.216: Mechanical power-transmission
apparatus

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

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

29. What happens if I don’t
don t
follow?
 Serious
 up to $7000 per violation
 Other than Serious
 discretionary but not more than $7000
 Repeat
 up to $70,000 per violation
 Willful
 up to $70,000 per violation
 Violations resulting in death- further penalties
g p
 Failure to abate
 $7000/day

30. The problem with OSHA….
Open for interpretation….
Find X.
X
3cm
4cm

31. How do you PROVE you are Safe?
ANSI NFPA RIA UL
Follow a recognized standard to
demonstrate your compliance

32. ANSI Standards
 American National Standards Institute (ANSI) are
voluntary standards developed by experts in the
industry.
ind str
 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

33. Voluntary Standards & The General
voluntary standard Clause establish the
Dutystandards typical
If OSHA determines that compliance with the
OSHA would have prevented or
lessened the severity of an injury,employers must
general standards OSHA may cite
g p y
A
An the
th temployer’s failure to l ll but standard OSHA
l d’ meet without specifying how.d as a
ANSI standard is
d i f not t law, b t can become
il t a follow the t d b
f th
violation of the general duty clause. to decide
gives the employer discretion
mandatory!
how best to achieve the standard’s
 This happens through aBut OSHA called “incorporation
goals process ( and the courts ) do
goals. incorporation
through reference”say how they EXPECT employers to a
when an OSHA standard cites
specific ANSI standard. discretion provided by the
use 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.

34. ANSI B11 Safety Standards
y
ANSI B11.22 - Turning Machines
AMT EHS - Environmental Health and Safety
ANSI B11.23 - Milling, Drilling and Boring Machines
ANSI B11 ASC - Accredited Standards Committee
ANSI B11.24 - Safety Requirements for Transfer Machines
ANSI B11.1 - Mechanical Power Presses
ANSI B11.TR1-2004 - Ergonomic Guidelines
B11.TR1 2004
ANSI B11 2 - H dra lic Po er Presses
B11.2 Hydraulic Power
ANSI B11.TR2-1997 - Mist Control Considerations
ANSI B11.3 - Mechanical Power Press Brakes
ANSI B11.TR3-2000 - Risk Assessment and Risk Reduction
ANSI B11.4 - Shears
ANSI B11.TR4-2004 - Selection of PES/PLC) for Machine Tools
ANSI B11.5 - Ironworkers
ANSI B11.TR5-2006 - Sound Level Measurement Guideline
ANSI B11.6 - Lathes
ANSI B11.TR6-200X - Control Reliable Circuits
ANSI B11.7 - Cold Headers and Cold Formers
ANSI B11.TR7-2007 - Lean Manufacturing
ANSI B11.8 - Drilling, Milling, and Boring Machines
ANSI B15.1-2000 - Mechanical Power Transmission Apparatus
ANSI B11.9 - Grinding Machines
ANSI B65.1-2005 - Printing Press Systems
ANSI B11.10 - Sawing Machines
ANSI B65.2-2005 - Binding and Finishing Systems
ANSI B11.11 - Gear and Spline Cutting Machines
ANSI B65.3-2001 - Guillotine Paper Cutters, Mill Trimmers
ANSI B11.12 - Roll-Forming and Roll-Bending Machines
ANSI B65.4-2002 - Three Knife Trimmers
B65 4 2002 Three-Knife
ANSI B11.13 - Chucking Machines
ANSI B65.5-2006 - Stand-Alone Platen Presses
ANSI B11.14 - Coil Slitting Machines
ANSI B151.27 - Plastics Machinery Robots
ANSI B11.15 - Pipe, Tube, and Shape Bending Machines
ANSI B155.1-2006 - Packaging Machinery
ANSI B11.16 - Powder/Metal Compacting Presses
ANSI B56.5 - Industrial Vehicles
ANSI B11.17 - Horizontal Hydraulic Extrusion Presses
ANSI/ASSE Z244.1 - Control of Hazardous Energy gy
ANSI B11.18 - Plate From Coiled Configuration
B11 18
ANSI/RIA R15.06 - Industrial Robots and Robot Systems
ANSI B11.19 - Performance Criteria for Safeguarding
ANSI/RIA TR R15.106 - Teaching Multiple Robots
ANSI B11.20 - Integrated Manufacturing Systems
ANSI/RIA TR R15.206 -Guidelines for Implementing
ANSI B11.21 - Lasers for Processing Materials

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

36. S
So………What should I do to safeguard my
Wh h ld d f d
machine?

37. ANSWER:
Review Applicable Standards
and Conduct an Assessment

39. What is it?
 Risk Assessment
The process by which the intended use of the
machine, the tasks and hazards, and the level
of risk are determined
 Risk Reduction
The application of protective measures to
reduce the risk to a tolerable level

40. 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 Tools
ANSI/RIA R15.06-1999 – For Industrial Robots and Robot Systems – Safety
Requirements
ANSI/NFPA 79-2007 – Electrical Standard for Industrial Machinery
ANSI/ASSE Z244.1-2003 – Control of Hazardous Energy – Lockout/Tagout and
Alternative Methods
ANSI/PMMI B155.1-2006 – Standard for Packaging Machinery and Packaging-Related
Converting Machinery – Safety Requirements for Construction, Care, and Use
CSA Z432-04 – Safeguarding of Machinery – Occupational Health and Safety
CSA Z434-03 – Industrial Robots and Robot Systems – General Safety Requirements
CSA Z460-05 – Control of Hazardous Energy – Lockout and Other Methods
EN 1050:1996 / ISO 14121:1999 – Safety of machinery – Principles of risk assessment
EN 954-1:2000 / ISO 13849-1:1999 – Safety of machinery – Safety-related parts of control
systems – Part 1: General principles of design
ISO 12100-1:2003 – Safety of machinery – Basic Concepts, general principles for design –
Part 1: Basic terminology, methodology
ISO 12100-2:2003 – Safety of machinery – Basic Concepts, general principles for design –
Part 2: Technical principles

41. How do I do it?
 Pick a standard to follow
follo
ANSI, CSA, ISO
 Y can create your own process, as l
You t long
as it’s based on industry best practices
 You can conduct the process in house,
house
request it from your OEM, or contract an
outside service provider

42. Risk Assessment Matrix
from ANSI/RIA R15.06-1999
Table 2
Severity of Exposure Exposure Avoidance Risk Reduction Category
E2 Frequent A2 Not Likely R1
S2 S i I j
Serious Injury
Exposure A1 Likely R2A
More than
E1 Infrequent A2 Not Likely R2B
First-aid
Exposure A1 Likely R2B
E2 Frequent A2 Not Likely R2C
S1 Slight Injury Exposure A1 Likely R3A
First-aid E1 Infrequent A2 Not Likely R3B
Exposure A1 Likely R4
Table 2 - Risk reduction decision matrix prior to safeguard selection
p g

43. Risk Reduction Measures
from ANSI/RIA R15.06-1999
Table 3
Category SafeGuard Performance Circuit Performance
Hazard Elimination or hazard substitution
Control Reliable (4.5.4)
R1 (9.5.1)
Engineering controls preventing acess to Control Reliable (4.5.4)
R2A
the hazard, or stopping the hazard (9.5.2),
e.g. interlocked barrier guards, light Single Channel with monitoring (4.5.3)
R2B curtains,
curtains safety mats or other presence
mats,
sensing devices (10.4) Single Channel (4.5.2)
R2C
Single Channel (4.5.2)
R3A Non interlocked barriers, clearance,
, ,
procedures and equipment (9.5.3)
Simple (4.5.1)
R3B
Awareness means (9.5.4) Simple (4.5.1)
R4
Table 3 - Safeguard Selection Matrix

44. If there are Hazards, there MUST be Risk
Reduction
PROTECTIVE MEASURE EXAMPLES
This can only be
Most Effective Eliminate human interaction in the process
Elimination or Substitution done by the OEM
Eliminate pinch points (increase clearance)
Automated material handling (robots, conveyors, etc.)
Barriers
Engineering Controls Interlocks
(Safeguarding Technology / Presence sensing devices (light curtains, safety mats, area scanners, etc.)
Protective Devices) Two hand control and two hand trip devices
So what is the
Awareness Means
Lights, beacons, and strobes
Computer warnings
difference between These 3 rely
y
Signs and labels
Beepers, horns, and sirens
these 3 sections?
Training and Procedures on human
Safe work procedures
Safety equipment inspections
(Administrative Controls) Training
Lockout / Tagout / Tryout
behavior!
Safety glasses and face shields
Personal Protective Equipment Ear plugs
(PPE) Gloves
Protective footwear
Least Effective Respirators
Hierarchy of Control

45. If there are Hazards, there MUST be Risk
Reduction
PROTECTIVE MEASURE EXAMPLES
Most Effective Eliminate human interaction in the process
Elimination or Substitution Eliminate pinch points (increase clearance)
Automated material handling (robots, conveyors, etc.)
Barriers
Engineering Controls Interlocks
(Safeguarding Technology / Presence sensing devices (light curtains, safety mats, area scanners, etc.)
Protective Devices) Two hand control and two hand trip devices
Lights, beacons, and strobes
Awareness Means Computer warnings
Signs and labels
Beepers, horns, and sirens
Safe work procedures
Training and Procedures Safety equipment inspections
(Administrative Controls) Training
Lockout / Tagout / Tryout
Safety glasses and face shields
Personal Protective Equipment Ear plugs
(PPE) Gloves
Protective footwear
Least Effective Respirators
Hierarchy of Control

49. What do you think the number of
machines we conducted 10 000
10,000
Risk Assessments on were
guarded correctly?
7%
Their current guards proved to be a waste of time and money when done incorrectly!

50. If You don’t………..

51. What are Hazards on a Machine or
Process?
• Physical • Electrical
• Falling / Moving Objects • Fl h
Flashover and B
d Burns
• Collisions • Electrocution
• Collapsing Structures • Wrong Connection / Loose Connection
• Chemical • Mechanical / Process
• Explosion • Pinch Points or Entanglement
• Fire • Abrasion, Grinding,
Abrasion Grinding Cutting
• Toxic Material Release • Thermal
• Wrong mix of chemicals • Pressure Releasing Effects (Bursting Vessels,
• Radiation Jets of Gas or Liquids)
• Welding Torches, Gases etc.
Hazards are physical objects or chemical substances that have the
potential f causing h
t ti l for i harm t people, property or the environment
to l t th i t

52. What methods for machine safety
are there?
 Guards  Location/distance
 fixed
 interlocked  Feeding and ejection methods
 adjustable  automatic and/or semi-
semi
 self-adjusting automatic feed and
ejection
 Devices  robots
 presence sensing
 pullback  Miscellaneous aids
 restraint  awareness barriers
 safety controls (tripwire cable,  protective shields
two-hand control, etc.)  hand-feeding tools
 gates

53. What methods for machine safety
are there?
 Guards  Location/distance
 fixed
 interlocked  Feeding and ejection methods
 adjustable  automatic and/or semi-
semi
 self-adjusting automatic feed and
ejection
 Devices  robots
 presence sensing
 pullback  Miscellaneous aids
 restraint  awareness barriers
 safety controls (tripwire cable,  protective shields
two-hand control, etc.)  hand-feeding tools
 gates

54. What methods for machine safety
are there?
 Guards  Location/distance
 fixed
 interlocked  Feeding and ejection methods
 adjustable  automatic and/or semi-
semi
 self-adjusting automatic feed and
ejection
 Devices  robots
 presence sensing
 pullback  Miscellaneous aids
 restraint  awareness barriers
 safety controls (tripwire cable,  protective shields
two-hand control, etc.)  hand-feeding tools
 gates

55. Safety Distance Formula
From ANSI/RIA R15.06-1999 Annex B

56. Otherwise……

57. Safe Mounting Distance Formula
Total
Stopping
Time
Ds = K(Ts) + Dpf
Hand
Safe Speed Depth
Mounting
M ti Constant Penetration
P t ti
Distance 63 inc/sec Factor

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

59. Products used to safeguard

60. MS4800 – T
Two B
Box
 All models can be
cascaded
 Cascade up to 4
p
segments (256 beams
max)
 Key features: IBI’s – easy
to align, diagnostics

61. F3SJ – Two Box
 You pick the resolution
 You pick the height
 Cascadable
 Key features: Sophisticated
muting – single beam bi
beam, bi-
directional, outputs can be
modified via offline editor

62. Light Curtain Accessories
 EP Enclosures
available for
protected
heights of 10” to
48
48”
 IP67 enclosures
- 10” to 82”

63. Interlock Switches: Three Basic
Categories
 Traditional mechanical switch
 Non Contact
 Solenoid-locking
 D I need a monitoring relay?
Do d it i l ?

64. D4NS Compact Plastic Door
Switch
 O ti
Optional metal
l t l
operation head
 9 different conduit
entrances / M12
connector
 6 different internal
switch configurations
Up to 3 contacts
p
 Key feature: 20% -
30% lower price than
non-OSTI brands
OSTI b d

65. D4GL Keyed Solenoid Door
Switch
 Si il to new D4NL,
Similar t D4NL
features “in-line”
construction
 up t 3 sets of safety
to t f f t
contacts and 2 solenoid
monitoring contacts
 k h ldi
key holding fforce of 1000N
f
 metal operation head
 Key feature: 20% - 30%
lower price than non-OSTI
brands

66. AA-43 D4GL-SK10-LK
 Solenoid locking switch and
integral slide bolt
 LEDs for open/close/locked
 Integral lock-out key
 Up to 5 contacts
 Power to lock or power to
unlock
 24 Vdc only
 No rear release

68. D40A/G9SX-NS
Compact Non-Contact Door Switch/
Flexible Safety Unit

69. Advantage over Magnetic Switches
Competitor’s 6 units max
(w/LED)
D40A-(Up
D40A (Up to 30 units w/LED )

70. Advantage over Magnetic Switches
On machines with a lot of doors,
it is difficult to know
which d
hi h door i opened.
is d
Solution
Even half-opened door is indicated by
Auxiliary output
＋
－
Yellow line is Auxiliary output Signal
Signal

71. Safety Mats
 UMQ Quick
Disconnect now
available
 Send us your
drawings to
ensure proper
dimensions
di i
 Key features –
durable, easy to
configure

72. You give us this

73. We give you this

74. OS3101: New and Improved
 Key features:
 Very easy to p g
y y program
 LED sector indicators
 Diagnostic display
g p y
 Now has multiple zones

75. OptoShield Operating Principle
D = (c x T)/2
Distance to object determined by the “time of flight” of the light pulse.

76. OptoShield Operating Principle
Pulses sent out in 180o

77. Screen Layout
Menu
Bar
Tool
Bar
Info Bar Warning Zone Safety Zone

78. NE1A Programmable Safety
Modern network safety technology
Controller easily segment an
makes it possible to instantly safety-
stop a machine,
application Safetysafety zones or
 Intelligent into Network
Controller
quickly1.diagnose a safety device
 Safety Logic functionality
 2. DeviceNet Safety Master Functionality
 3. DeviceNet Slave Functionality
 4. Local safety I/O
 Easy Programming
 Safety based function Block
 Program Size: Max 128 Function Blocks
 Logic Editor contained within Configuration
Software
 Local Safety and Slave I/O
 Password Security
 USB Port for Programming
 Global Safety Standards

79. 2) Through the Logic Program
) g g g
FAULT!

80. Questions?