T24 Improving Productivity Using Contemporary Safety Designs

Transcription

1 CO900H Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. T24 Improving Productivity Using Contemporary Safety Designs PUBLIC

2 Copyright 2016 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

3 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety as a Core System Function Safety continues to emerge as core system function. Safety is a Key Differentiator: Global Compliance Common Designs Reduced Costs Increased Productivity Systematic MTTR Reduction Improved Competitiveness Reduced Floor Space and Direct Labor Improved Ergonomics

4 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, Inc. 4 All Rights Reserved. Safety as a Core System Function But How? New Tools: Emergence of Global Standards ISO, IEC 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

5 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, Inc. 5 All Rights Reserved. Functional Safety Life Cycle STEP 5 MAINTAIN & IMPROVE SAFETY SYSTEM STEP 1 RISK OR HAZARD ASSESSMENT Functional Safety Life Cycle STEP 4 SAFETY SYSTEM INSTALLATION & VALIDATION STEP 3 SAFETY SYSTEM DESIGN & VERIFICATION STEP 2 SAFETY SYSTEM FUNCTIONAL REQUIREMENTS

6 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 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 Cross- Functional Team Determination of Machinery Limits & Functions Identification of Tasks & Associated Hazards Risk Estimation & Evaluation Risk Reduction and Mitigation Residual Risk Determination Documentation Ref: ANSI/RIA TR R

7 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, Inc. 7 All Rights Reserved. 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

8 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, Inc. 8 All Rights Reserved. OSHA Minor Servicing Exception Permitted by OSHA if: Alternate Method provides equivalent Protection Risk Assessment performed to determine Equivalency System provides Exclusive Control

9 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. ANSI/ASSE Z244.1 Alternative Methods Compliments OSHA Minor Servicing Control of Hazardous Energy Lockout/Tagout and Alternative Methods Provides additional guidance Requires Risk Assessment

10 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Improved Productivity by Design: MTTR Reduction Typical Downtime Event Running Down Running MTTR = 12 minutes (avg.) Machine Stops Maintenance Arrives Fault Identified LOTO Repair Performed Machine Unlocked Repair Tested Machine back in Auto Production Resumes

11 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 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

12 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 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

13 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 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

14 Copyright 2016 Rockwell Automation, 14 Inc. All Rights Reserved. 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!

15 Copyright 2009 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, 15 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

16 Safety System Optimization Safe Distance Table 6 from ANSI/RIA PUBLIC Copyright 2009 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, 16 Inc. All Rights Reserved.

17 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization - Example Valve bank Operator Tool or Fixture

18 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization - Example Valve bank Operator Tool or Fixture Motion Causing Output Power

19 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization - Example GLx SIO SIO SIO Valve bank Operator Tool or Fixture Motion Causing Output Power

20 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization - Example GLx. Tc = ID + SIO SIO SIO 4 * IRPI (CRTL) + ST Period + ST Scan (Safety Watchdog) + ORPI + Operator Tool or Fixture Valve bank Motion Causing Output Power OD. = (24) = 243 ms (single Fault) Ref: Ds = K(Tr + Ts + Tc) + Dpf

21 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization - Example GLx SIO SIO CR-30 Valve bank Operator Tool or Fixture Motion Causing Output Power

22 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization - Example GLx SIO SIO CR-30 Operator Tool or Fixture Valve bank Motion Causing Output Power. Tc = CR-30 Scan. = 45ms Ref: Ds = K(Tr + Ts + Tc) + Dpf

23 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization - Results GLx SIO SIO CR-30 Results: Tc (reduced) = TcGLx TcCR-30 = 243 ms 45 ms = 198ms Operator Tool or Fixture Valve bank Motion Causing Output Power Ds (reduced) = 0.198s * 63 Over 12 Ds Reduced. Ref: Ds = K(Tr + Ts + Tc) + Dpf

24 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Cost Analysis Reduced System Floorspace 12 reduction X 4 load window width = 4 sq ft per load window reduced 4 sq ft X 150 load windows/shop = 600 sq ft/shop reduced floorspace 600 sq ft X $100/sq ft/yr = $60K/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 12 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

25 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri 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? Ref: Ds = K(Tr + Ts + Tc) + Dpf Can we affect Tr or Ts? What about Dpf? Safety System Optimization Requires a Systematic Approach

26 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri Safety System Optimization New Thinking Safe Motor Control Controlling the Hazard Typically either On or Off today STO, 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 MSR-57 New Safety Technologies will Change the way Hazards are Managed

27 Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. Copyri 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 MSR-57 Work

28 Copyright 2009 Rockwell Automation, Inc. All rights reserved. Copyright 2016 Rockwell Automation, 28 Inc. All Rights Reserved. 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 Work

29 CO900H Copyright 2015 Rockwell Automation, Inc. All Rights Reserved. Thank You! PUBLIC