The New Machinery Directive is Here!

Five Steps to Safety

Safety doesn’t have to be complicated or confusing. Here are five steps you can take to ensure you are up-to-date with safety standards.

1) Join a standards committee.
Joining a standards committee gives you first hand knowledge of changes to standards.


2) Join an organization that provides trade shows and seminars.
By joining an organization that provides trade shows and seminars you expand your knowledge base and mindshare. Trade shows and seminars are great opportunities to not only learn about new standards but to also see new technologies available to help you meet those standards. Networking at these events also gives you the chance to utilize colleagues as sounding boards for issues or problems you may have with safety.

3) Create an internal safety committee
An internal safety committee is a great way to enforce safety regulations. Schedule monthly assessments of machinery and procedures to ensure that employees are performing duties in a safe manner. Monthly assessments also give you the opportunity to be proactive in solving issues before they become emergencies.

4) Benchmark another company that has a good safety history
By benchmarking a leader in safety you can assess your current safety policies and measures to ensure they line up with a company that has a proven track record with safety. Benchmarking allows you to see how other companies have handled similar situations and follow their lead.

5) Schedule a plant and risk assessment with an outside safety company.
Companies that perform plant and risk assessments are experts in safety. They have knowledge of the newest standards and what steps need to be taken to implement the latest regulations. When a risk assessment is performed a documented physical examination and inspection of either a single machine or an entire plant, is carried out under the guidelines of applicable national and/or international standards. Safety improvement on existing machines can be prioritized and implemented based on known risks, thereby extending the working life of the machine. Early identification of hazards on new machines will save time and money by facilitating the integration of appropriate safety measures.

A typical risk assessment includes:
• Identification of applicable standards, regulations and best industry practices.
• Statement of machine limits
• Examination of all hazards throughout the relevant machinery lifecycle phases
• Estimation and evaluation of risk
• Recommended approach for risk reduction

For more information on the issues mentioned in this article please email marketing@pilzusa.com

For more information on Pilz Services please email consulting@pilzusa.com

My company designs large machines and automated production lines. Are there new requirements to consider?

There are a number of requirements you should consider. the existing directive required that "From the main control position the operator must be able to ensure that there are no exposed persons in the danger zones" (before starting or restarting machines). Considering the risks in large machines and production lines the new directive demands the same can be achieved from all control positions. However, recognizing advances in technology the new directive introduces the obligation to consider in certain circumstances control systems and protective devices to automatically prevent start-up if it detects somebody in a danger zone.

Software for safety functions on plant and machinery.

These days, software used in mechanical engineering is not just limited to classic areas such as the programming of logic controllers (PLC) or human machine interfaces (HMI); increasingly it must also undertake safety functions.

In order to meet these requirements, safety relay manufacturers are increasingly offering freely programmable systems. Externally they are designed just like standard PLCs, but they are usually characterized by multi-channel structures. The principle of redundancy guarantees safety through cross-monitoring. Read more

The directive stipulates that:

Particular attention must be given to the following points:

• the machinery must not start unexpectedly
• the parameters of the machinery must not change in an uncontrolled way, where such change may lead to hazardous situations"

Parameter monitoring systems, such as low speed run, which through risk assessment are considered as a risk reduction measure must be implemented in accordance with appropriate devices and systems. Risk assessments must also identify normal or abnormal conditions which could lead to an unexpected start up and prevent such start up through the safety related control system.

The body plant of the future

http://www.pilzamerica.com/articles/Pilz-The-body-plant-of-the-future.pdf

How can a machine control system designer consider that "reasonably foreseeable human error during operation does not lead to hazardous situations"?

The obligation to consider 'reasonably foreseeable misuse' related not only to control systems but is reflected in the general principles of the "Essential Health and Safety Requirements". The term 'reasonably foreseeable misuse' means the use of machinery in a way not intended in the instructions for use, but which may result from readily predictable human behavior.

While similar principles are enunciated in other standards including EN ISO 12100, this statement is particularly onerous. The control system designer needs to be conscious of the risk assessment and the measures for risk reduction that are dependent on the control system. The ease ofuse and ergonomics of the machine interface and its relationship to the control system are critical. Studies show that the probability of a safety system being "bypassed" is proportional to the "benefit" of bypassing the system. Therefore to avoid predictable behavior of system bypass, the design of the safety system should be considered in a manner where machine operators do not benefit or gain incentive from bypassing safety systems. Intelligent safety concepts including zoned safety systems, boundary less guarding, safe mode enabling and safe monitoring of machine parameters should be considered by the control system designer.

What are the important changes impacting machine control systems?

The obligations on machine control system designers are more explicitly and in some cases more stringently defined. Consider the following:
"Control systems must be designed and constructed in such a way as to prevent hazardous situations from arising. Above all, they must be designed and constructed in such a way that:

• they can withstand the intended operating stresses and external influences
• a fault in the hardware or software of the control system does not lead to hazardous situations
• errors in the control system logic do not lead to hazardous situations
• reasonably foreseeable human error during operation does not lead to hazardous situations."

These requirements restate with clarity that a failure of or any other cause in a machine control system should not lead to a hazardous situation. The new wording reflects the state of the art in control system technology, where there is a distinction between software and hardware.

3D Sensor Allows for Quick Changeovers And Reduced Downtime

http://www.pilzamerica.com/articles/3D-Sensor-Allows-for-Quick-Changeovers.pdf

The approach to machinery design and the technologies used have changed significantly since 1989, how is this reflected in the requirements of the directive?

Is it true that there are many changes in the way machines are designed and constructed with increased use of electronic and software based control systems, modular construction of production lines and increased use of robotic systems. There are many changes in the essential requirements reflecting such changes particularly related to control systems and devices.

Defying the conditions

http://www.pilzamerica.com/articles/Pilz-Defying-the-conditions.pdf

One control system for safety and process functions

http://www.pilzamerica.com/articles/Pilz-Ford-PSS.pdf

How is the interaction between machine operators and machinery considered?

The consideration of the interaction between machine operator and machine is critical to safety. Ergonomics has received special attention in the new directive with a specific section laying out the requirements. There is now a strongly defined requirement on machine designers to give more consideration to this aspect of major importance to the machine operators. In this respect the safety concepts selected to reduce the risk to workers from a contact with moving parts of machinery can have a serious impact. Physical guarding may significantly impact

• how a worker interacts with a machine
• the repetitive effort used by workers
• the audible and visual sensory feedback provided to the operator

Effective risk assessment followed by the generation of intelligent safety concepts can significantly benefit the ergonomic design of machines.

The innovative PSENslock series

The innovative PSENslock series, from Pilz Automation Safety L.P. the German manufacturer of safe automation components and systems, takes safety to a new level. It operates magnetically, not mechanically, as do the more traditional systems. "The PSENslock non-contact magnetic interlocking gate switch is an outstanding alternative to traditional mechanical gate switches," said Sales Engineer Ben Harper. "It's safer because it combines secure safety gate monitoring and a non-contact magnetic interlock within the same unit. And because it's mechanically non-wearing, PSENslock has a longer service life."

PSENslock has an electro-magnetic holding force of either 500 N or 1000 N to prevent the unintentional opening of swing gates and sliding gates. Its proven transponder technology is manipulation proof because the switch and actuator are totally different items. This provides an additional measure of safety. Existing mechanical technology, on the other hand, requires the use of a keyed actuator. Consequently, it's possible that this "key" could be damaged, suggesting the door is closed, creating a potentially unsafe condition. Ideal for use in rugged industrial environments, PSENslock is easy to install. With its combination of safe position monitoring and process guard locking, it's suitable for mounting onto standard 45mm profiles around the machine.

PSENslock can be used on flap gates and safety gates and is extremely tolerant to gate misalignment. With bright, double-sided LED diagnostics on both sides; it can be mounted left or right handed. An M12 plug connection allows for simple assembly. "It's really quite an achievement," Harper added. "In addition to the longer life cycle, ease of installation, higher tolerance to alignment, and strong holding force, the PSENslock has the option to include a fully coded switch which is more difficult to defeat and can be wired in series while maintaining the high safety categories that many applications demand."

PSENslock is designed for applications up to SIL3 in accordance with EN/IEC 62061, Category 4 in accordance with EN 954-1 and protection type IP67. In terms of a complete solution, PSENslock can be connected to all Pilz evaluation devices.

Pilz manufacturers a line of safety equipment used in plants. These sensors, relays and other components can be applied as individual pieces or group components to machines throughout many industries where man and manufacturing equipment are utilized together, including automotive, robotics, packaging, amusement, and wind power. The company also provides a wide array of safety consulting services.

What new requirements impact machine instructions?

Safe operation of machinery depends on clear instructions. The obligations on machine designers to provide clear information on machine use and the hazards to be expected in operating and using machines are elaborated in detail in the new directive. The contexts of the instructions must cover not only the intended use of the machinery, but also take into account any reasonably foreseeable misuse. Other essential contents include:

• information about th eresidual risks that remain despite the inherent safe design measures, safeguarding and protective measures adopted;
• instructions on the protective measures to be taken by the user, including, where appropriate, the personal protective equipment to be provided;
• the operating method to be followed in the event of accident or breakdown and the unblocking of a machine.

A safe, clean business

Ready to go?

http://www.pilzamerica.com/articles/Pilz-Ready-to-go.pdf

How can I manage situations where there are different assessments of the same risk by different machine builders?

Machine risk assessment is part qualitative, part quantitative requiring judgment by competent persons. Consequently there is likely to be a dispersion of the results achieved by different manufacturers or their authorized representatives when carrying out a risk assessment on the same or similar equipment. With the strength of the obligation in the directive machine builders may expect that machinery buyers and statutory authorities will seek more opportunity to examine the procedures followed, the assumptions and judgments made, and the results achieved.

Additionally the demands on machine builders to provide more detailed instructions will provide traceability between Risk Assessment and Instructions.

New Pilz website has more to offer!

Whatever the reason for undertaking a formal risk assessment on machinery or work equipment, Pilz consultants can provide an impartial service. Risk assessments are encountered in almost every walk of life, even for crossing the road. But when it comes to machinery, a formal risk assessment needs certain requirements to be fulfilled, and the person performing the risk assessment must be competent to do so.

While some companies have personnel who are competent to perform formal risk assessments on machinery, others appreciate that they lack the competence and therefore need support from consultants. There are also occasions when companies are busy and do not have the resources available when required, or they may choose to use an independent service provider for this critical task.

For any of these scenarios, the consultancy division of Pilz Automation Safety L.P. can undertake risk assessments on machines or machine designs in accordance with the requirements of relevant standards. Each assessment identifies the hazards present, estimates and evaluates the risks, and determines and outlines the measures that may be applied to reduce the risks to acceptable levels.

As part of the risk assessment, the consultants identify applicable standards, regulations and best industry practices, prepare a statement of the machine’s limits, and examine all hazards throughout the relevant machine lifecycle phases.

Because Pilz consultants have decades of experience of machine safety, their advice related to risk-reduction measures is particularly useful. This is in contrast to some other consultants that can highlight problems but are unable to advise on pragmatic, cost-effective risk-reduction measures.

Furthermore, if the client requires ongoing support, Pilz can provide engineering services to take the safety concept forward, and even supply products to implement a safety-related control and monitoring system. Alternatively, the client can take the consultants’ risk assessment report and carry out the necessary work in-house or work with a third-party supplier or system integrator of their choice.

For more information on the issues mentioned in this article please email marketing@pilzusa.com

For more information on Pilz Services please email consulting@pilzusa.com

Can I demand a copy of a risk assessment from the machine builder?

Certain social partners including European trade unions lobbied for a requirement that Risk Assessments be supplied with machinery to create more transparency and to compensate for such variations in assessment. However, it is not mandatory for machine builders to provide a risk assessment.