- Rockwell Automation

Transcription

T65 – Improving Productivity Using
Contemporary Safety Designs
PUBLIC
PUBLIC - 5058-CO900H
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Agenda
Safety as a Core System Function
Functional Safety Life Cycle
Emerging Design Philosophies
Application Examples – Configurable Designs
Application Example – System Optimization of Tc
Advanced Safety Concepts
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Safety as a Core System Function
 Safety continues to emerge as core system function
 Value – Safety as a Key Differentiator:
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
Global Compliance

Common Designs

Reduced Costs

Increased Productivity –

Systematic MTTR Reduction

Improved Competitiveness

Reduced Floor Space and Direct Labor

Improved Ergonomics
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Copyri
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”
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Copyright © 2010 Rockwell Automation, Inc. All rights reserved.
4 All Rights Reserved.
Copyright © 2015 Rockwell Automation, Inc.
Functional Safety Life Cycle
STEP 5
STEP 1
MAINTAIN & IMPROVE
SAFETY SYSTEM
RISK OR HAZARD
ASSESSMENT
Functional Safety
Life Cycle
STEP 4
SAFETY SYSTEM
INSTALLATION &
VALIDATION
STEP 2
STEP 3
SAFETY SYSTEM
FUNCTIONAL
REQUIREMENTS
SAFETY SYSTEM
DESIGN & VERIFICATION
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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)
Steps Include:
 Identification of CrossFunctional Team
 Determination of Machinery
Limits & Functions
 Identification of Tasks &
Associated Hazards
 Risk Estimation & Evaluation
 Risk Reduction and Mitigation
 Documentation
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Performance
Level, PLr
P1
F1
S1
Task/Hazard
a
P2
P1
b
P2
P1
c
Contribution
to Risk
Reduction
Low
F2
F1
P2
S2
P1
d
F2
P2
S = Severity
F = Frequency or Duration of Exposure
P = Avoidance Probability
e
High
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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
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Improved Productivity by Design: MTTR Reduction
Typical Downtime Event
Running
Running
Down
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Production Resumes
Machine back in Auto
Repair Tested
Machine Unlocked
Repair Performed
LOTO
Fault Identified
Maintenance Arrives
Machine Stops
MTTR = 12 minutes (avg.)
Safety Application - Perimeter Guarding
Point of Entry Configurable Safety System
Gate Entry Box
Robots
• OFF (AUTO)
• Outputs ON, Servos OFF
• Outputs ON, Servos ON
Tooling
• OFF (AUTO)
• Tool Outputs ON, Transfer Motion OFF
• Tool Outputs ON, Transfer Motion ON
Easy, Intuitive and Secure
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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
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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)

Value of safety solution due to
improved productivity (reduced MTTR)
$10K X 2min X 3000 =
$60M/yr.
Safety = Productivity = Profitability
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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!
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Inc. All Rights Reserved.
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
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Safety System Optimization – Safe Distance
Table 6 from ANSI/RIA 15.06
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Safety System Optimization - Example
Valve
bank
Operator
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Tool or
Fixture
Valve
bank
Operator
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Tool or
Fixture
Motion Causing
Output Power
GLx
SIO
SIO
SIO
Valve
bank
Operator
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Tool or
Fixture
Motion Causing
Output Power
GLx
SIO
SIO
SIO
Valve
bank
Operator
Tool or
Fixture
Motion Causing
Output Power
.
Tc = RPI + GLx Scan + RPI
.
= 50ms + 20ms + 50ms
.
= 120ms
Ref: Ds = K(Tr + Ts + Tc) + Dpf
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GuardLogix
SG600
SIO
Tc = SG600 Scan
= 20ms (or less!)
Valve
bank
Operator
Tool or
Fixture
Motion Causing
Output Power
Over 6” Ds Reduced!
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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
Load Parts
Exit load window
Palm/Initiate Cycle
Total =
1.5 sec
5.0 sec
1.5 sec
1.0 sec
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
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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
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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

MSR-57
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
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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
MSR-57
Load
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Work
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!
MSR-57
Load
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Work
Thank You!
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www.rockwellautomation.com
PUBLIC - 5058-CO900H

- Rockwell Automation

Transcription

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