Safedesign: Machine Risk Assessment: Insert Photo Here

SafeDesign: Machine Risk Assessment
Insert Photo Here

Host: Dan Hornbeck Rockwell Automation Safety Business Development Manager
Copyright 2010 Rockwell Automation, Inc. All rights reserved.
Todays Agenda
1. Review of previous SafeDesign webinar 2. The value and necessity of risk assessment 3. The risk assessment process 4. Task and hazard identification 5. Risk mitigation and evaluation 6. The Rockwell Automation Safety Community and Future Educational Opportunities 7. Questions
Todays Speaker
Michael Kingsley, CFSE Machine Safety Consultant Rockwell Automation
Highlights from the Last Session

SafeDesign: Modern Safety Designs for Improved Safety & Productivity Safety as a Core System Function Functional Safety Life Cycle Emerging Design Philosophies
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
Functional Safety Life Cycle

MAINTAIN & IMPROVE SAFETY SYSTEM
STEP 5
RISK OR HAZARD ASSESSMENT
STEP 1
Safety Life Cycle
SAFETY SYSTEM INSTALLATION & VALIDATION

STEP 4
SAFETY SYSTEM DESIGN & VERIFICATION
STEP 3
SAFETY SYSTEM FUNCTIONAL REQUIREMENTS

6
STEP 2
Emerging Design Philosophies

Passive System Design
Ensures the safe way is the easy 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

Copyright 2010 Rockwell Automation, Inc. All rights reserved. 7
The Foundation: Begins with a Risk Assessment

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 to Global standards
Performance Performance Level, PLr Level, PLr
F1 S1 P1 P2 F2 P1 P2 F1 S2 F2 P1 P2 P1 P2
Contribution Contribution to Risk to Risk Reduction Reduction
a a b b c c d d e e
Low
Task/Hazard
S = Severity F = Frequency or Duration of Exposure P = Avoidance Probability
High
SafeDesign: Machine Risk Assessment

Insert Photo Here
Michael Kingsley, CFSE Machine Safety Consultant Rockwell Automation
The Purpose of Risk Assessment

The process serves as an effective tool for properly identifying and assessing the real hazards involved in operating a particular machine. Risk assessment provides a method for determining equivalent levels of protection when designing safeguards and stating OSHAs minor service exception. The process takes away the guesswork when estimating risk and prescribing safety system performance. Risk assessment is an active, documented process that can be filed and maintained for the entire life of the machine, and serves as documented proof of your due diligence. Risk assessment establishes the foundation and early framework for the design and implementation of an effective machine safety program.
As Referenced in U.S. Standards

Risk assessment is often referenced throughout mainstream U.S. machinery safety standards:
ANSI Z244.1
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ANSI B11.19
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ANSI / RIA R15.06
This standard provides a detailed risk assessment methodology
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NFPA 79
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In Europe
Risk assessment is a requirement for machinery directive compliance (2006/42/EC). Applies to those delivering CE compliant machinery to Europe.
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Why?
It is quite common for any group, whether it be a new equipment OEM or a facility end-user, to have a multitude of questions and concerns when starting at the beginning of the machine safety system lifecycle.
What does the word safety really mean, and how is it achieved? What is risk? How is it measured? Do I need a Ph.D. in mathematics to analyze probability and risk? How safe do I need to make this machine? How do I go about identifying hazards?
The most valuable attribute of a risk assessment process is that it answers most of these questions for us.
What is Safety Exactly?

Before we can understand what exactly we achieve through risk assessment, it will be important to provide an answer for the first few questions.
What does the word safety really mean, and how is it achieved? Safety, with respect to machinery operation is defined in IEC 62061:2005 as:
Safety is freedom from unacceptable risk

This immediately gives us a definition for safety in terms of risk, so it now starts to become more clear how risk assessment plays a part in achieving safety?!?
17
What is Risk?
Now we must define risk? Under the same standard, risk can be defined as: Risk is the combination of the Severity of harm, and the probability of occurrence of that harm (Frequency of Exposure + Avoidability).
What severity of harm would come to the skydiver if his parachute did not open?
+
What is the probability that the parachute(s) will not open and the skydiver will experience this harm?
Probability factors might be: How frequent does the person skydive?
+
If the parachute(s) do not open, is the skydiver able to avoid or limit the harm from the fall?
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Defined Risk Scale

If we can then define risk in terms of parameters that can be easily selected and summed together, then we will have a simple method for estimating risk relative to machine hazards. Risk assessment methodologies provided in machine standards provide this method through risk graphs and matrices, as we will see later. High Medium Low Negligible
Risk = Severity of Harm + Probability of Occurrence of Harm
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Acceptable Risk
Since safety is freedom from unacceptable risk, we will need to establish a value on our range that determines a threshold between acceptable, and unacceptable. Various standards will provide guidance on how to determine when acceptable risk has been achieved. High Medium Low Negligible
Acceptable Risk
Acceptable risk may differ from organization to organization, and therefore this value is not purely defined in any standard or methodology. The important thing is that your organization (and the risk assessment team) determine this threshold prior to starting the risk assessment.
Fundamental Process
Define all known machine characteristics and limits
Next Hazard
Hazard Identification
Risk Estimation
Risk Evaluation
Unacceptable
OK
Risk Reduction Complete for Particular Hazard
Risk Reduction
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Typical Worksheet
A typical risk assessment worksheet will look similar to the one below, with a column provided for each item of data that will be collected and/or determined.
22
Next Hazard
Risk Estimation
Risk Evaluation
Unacceptable
OK
Risk Reduction
23
The first pass of hazard identification is performed on the machine while ignoring all current safeguards that may be in place.
All risks must be identified and estimated It needs to be determined whether or not the existing safeguard and its performance are applicable and appropriate for the level of risk.
All tasks are broken down into individual steps

Allows each step to be assessed more thoroughly for exposure to hazards. Provides a flow and outline for the risk assessment process
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Considers ALL affected personnel
Operators and helpers, maintenance personnel Quality control, material handlers Engineers, technicians, sales personnel Trainees, supervisors, safety personnel Administrative personnel, passers-by
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Considers ALL tasks being performed on the machine
Packing, transportation, unloading, unpacking System installation, start up, commissioning Set up, try out, teach, operation (all modes) Tool change, planned and unplanned maintenance Troubleshooting, house cleaning, accident recovery And for CE, risk must be assessed entirely through to de-commissioning and disposal of the machine!
26
Considers ALL reasonably foreseeable hazard scenarios
Mechanical hazards: Crushing / Shearing / Cutting / Severing / Stabbing Entanglement / Drawing in / Trapping / Impact / Abrasion High pressure fluid injection / part ejection As well as other hazards such as Electrical, thermal, noise, vibration, radiation, dangerous substance handling, bad ergonomics, etc.
27
Considers ALL reasonably foreseeable hazard scenarios

Unexpected start-up Over-run, over-speed, or variations in operating speed (or any similar malfunction) Variations in the rotational speed of tools Failure of power supplies and various control circuits Systematic errors in software code / Specifications Effects of EMC / EMI Effects of the installed environment (Temp, moisture, etc.) Operator mode confusion Lack of proper procedures and/or training
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Typical Worksheet
With a task and hazard identified, we enter this data into our worksheet
Task Step
Hazard: a. Details of potential hazard b. Event leading to hazard or failure mode c. Hazardous Energy Source(s) d. Reference to a supporting photo or drawing.
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Risk Estimation
Next Hazard
Risk Estimation
Risk Evaluation
Unacceptable
OK
Risk Reduction
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Risk Graphs/Matrix/Chart
For example purposes, we will utilize the ISO 13849-1:2006 Risk Graph
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Risk Graphs/Matrix/Chart
But depending on our objectives, we could use various other methods. We should consider that one objective is to define our safety performance, and that our risk graph should provide a method for doing so..
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ISO 13849 Risk Estimation

13849-1/Annex A, Figure A.1
Step 1: Select Severity of the hazard.

Step 1 S1: Slight (normally reversible injury) S2: Serious (normally irreversible injury or death) * Note: Annex A will provide more detailed guidance on the selection of this parameter.
S2 F2 F1 S1 F2 P1 P2 P1 P2 F1 P1 P2 P1 P2
Performance Performance Level, Level,PLr PLr
a a b b c c d d e e
33

Step 2: Select Frequency and/or exposure to hazard.

Step 2 F1: Seldom to less often and/or exposure time is short F2: Frequent to continuous and/or exposure time is long * Note: Annex A will provide more detailed guidance on the selection of this parameter.
S2 F2 F1 S1 F2 P1 P2 P1 P2 F1 P1 P2 P1 P2
Performance Performance Level, Level,PLr PLr
a a b b c c d d e e
34

Step 3: Select Possibility of avoiding the hazard or limiting harm.

F1
Performance Performance Level, Level,PLr PLr Step 3

P1 P2 P1 P2 F1 P1 P2 P1 P2
a a b b c c d d e e
35
P1: Possible under specific conditions P2: Scarcely possible * Note: Annex A will provide more detailed guidance on the selection of this parameter.
S1 F2
S2 F2

We now enter the risk estimation parameter selections into our worksheet
Safety Function Performance Level (Determined from graph) Risk Parameters: Severity Frequency and/or Exposure Probability of avoiding hazard or limiting harm
36
Risk Evaluation
Next Hazard
Risk Estimation
Risk Evaluation
Unacceptable
OK
Risk Reduction
37

We now enter the risk estimation parameter selections into our worksheet
Risk Evaluation
1. We evaluate the initial risk 2. If risk is unacceptable, we must then evaluate the application of our existing and newly recommended safeguards and mitigation measures 3. We then adjust risk parameters affected by the existing and installed safeguards 4. Then evaluate the residual risk to determine if it is acceptable
38
Hierarchy of Risk Reduction Measures

Design it out Fixed enclosing guard Interlocked guard and safety devices Awareness means Training & supervision Personal protective equipment More Details in Future SafeDesign Webinars
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Risk Evaluation
The process of risk reduction may have to be implemented several times before the risk is mitigated to an acceptable value. Risk Estimation
Risk Evaluation
Unacceptable
OK
Risk Reduction Once the risk is acceptable, we can then move on to the next hazard.
40

Each step of a task will result in a completed worksheet (example below)
41
Documentation
Risk assessment documentation should contain the following information:
Information relevant for the machinery being assessed (machine limits, specs) Any relevant operational or design assumptions (loads, strengths, safety factors) Identified hazard scenarios The information on which the risk assessment was based; The data used and the sources (accident histories, experience through safeguarding similar machinery, etc.) The uncertainty associated with the data used and its impact on the risk assessment. Photos, video, and other supporting data. Risk reduction measures assessed and applied in the determination of risk reduction Residual risks associated with the machinery
42
Summary
Risk Assessment is the foundation for your machine safety program. Risk Assessment considers: The machine operating parameters and limits Task / Hazard identification Risk Estimation Risk evaluation / risk reduction measures Risk Assessment establishes the required safety performance for machine safeguards.
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Next Steps
Insert Photo Here
Where to Begin
Rockwell Automation Can Help You Get Started

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2010 SafeDesign Webinar Series

Rockwell Automation is hosting an ongoing series of educational webinars to provide the most current information on Functional Safety Directives and Practices.
Our next webinar will be:
May 4th, 2010

SafeDesign: Risk Mitigation Techniques
Hierarchical approach to safeguarding Designing out hazards and risks Engineered solutions
*Invitations and announcements with all the details will be forthcoming. Exact time subject to change.
46
Join our Safety Community

Rockwell Automation Safety Portal
http://discover.rockwellautomation.com/Safety
RAGuard http://www.twitter.com/raguard
Safety Automation Forum group http://www.linkedin.com/groups?gid=1950912
Rockwell Automation Safety Solutions

November 2, 2010 Orlando, FL
www.safetyautomationforum.com
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Questions?
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SafeDesign: Machine Risk Assessment

Insert Photo Here

Copyright 2010 Rockwell Automation, Inc. All rights reserved.

Michael Kingsley, CFSE Machine Safety Consultant Rockwell Automation

Highlights from the Last Session

Safety as a Core System Function

Copyright 2010 Rockwell Automation, Inc. All rights reserved.

Functional Safety Life Cycle

RISK OR HAZARD ASSESSMENT

Safety Life Cycle

SAFETY SYSTEM INSTALLATION & VALIDATION

SAFETY SYSTEM DESIGN & VERIFICATION

SAFETY SYSTEM FUNCTIONAL REQUIREMENTS

Emerging Design Philosophies

Configurable System Design

Lockable Safety Systems

Safety AND Productivity

The Foundation: Begins with a Risk Assessment

Contribution Contribution to Risk to Risk Reduction Reduction

S = Severity F = Frequency or Duration of Exposure P = Avoidance Probability

Copyright 2010 Rockwell Automation, Inc. All rights reserved.