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this is the first in a series of about ten webinars that we're going to have on some functional safety more of a technical view of safety requirements and implementation this is going to be pretty non product specific we're not going to be saying how to wire our light curtain specifically or how to set up our roto scanner specifically we're going to look at it more of a broad broad view of safety in general and how it should be implemented the safest in the correct way according to OSHA guidelines Nancy guidelines so that we can all be safe so the purpose of this is going to be like I said non going webinars focusing on the technical aspects of machine safety to help everybody better understand recognizing what hazards are present and the correct way to safeguard them anybody who's been in a plant has seen a machine with light curtains put on it that maybe has not been put on in the correct way we all know that just because you put a safety device on machine does not mean that that machine is now safe so hopefully we can give you the information you need to put it on the correct way mount it the correct way and other things of that nature this first webinar we're going to be going through is just kind of an introduction to safety we're not going to get too technical and any of the things we're speaking about but we should give you a couple of good benefits of why we need a safe environment and some of the quick ways we can check on things future webinars we're going to be having are going to be more technical and there'll be a little more specific to individual topics and towards the end of the webinar here will show you a list of some of those topics that are coming up something that we're definitely open to is if there are situations that you have come across in the past or something you see rather frequently that you maybe have questions on feel free to always email me at the end of the webinar my email will be on there as well as mark smoke woods who is our safety product manager and if you have any recommendations for maybe some training topics that you'd like to see in the future by all means let us know and maybe we'll put that on list / for the future so this series really is intended for anybody who designs machines build machines modify and stall operate maintain any type of machine guarding safety devices anybody who's in sales of these items as well distributors in in particular it's good to have this information to know when you're quoting out a system what all is really necessary to make it a safe system as I said before just throwing a light curtain on something doesn't make it safe we need to know and look at the whole big picture of what is necessary to make that machine safe it's also for anybody who's concerned with any type of safety training anybody who does EH&S at any plan and you're looking for specific guidelines to kind of you know help you pick things out it's also people like that so what what are the real benefits of us having safety well one of the easiest and best ways to make this visible is money everybody wants money so obviously when you have a lost-time accident or any type of an accident like that there's always the immediate cost that you see just from the accident but there's also those hidden costs such as your workman's comp experience multipliers your insurance premiums all that's affected by any of your safety issues that you may have as you see here we have a couple examples of a couple companies that brought their experience modification rate down and save themselves two hundred thousand dollars in one year and another one here showing they saved 82,000 per year over the last three years just by bringing their experience modification rate down so if you look at it in a big picture type of way national safety council estimates a worker with no lost time accident which would be one of the you know more minor type accidents costs about seven thousand dollars on average so if you want to cover those costs with your profit for example a company making a profit margin of three percent versus a five-thousand-dollar cost for the accident that equals a hundred and sixty seven thousand dollars and extra sales that are needed based on that three percent margin to cover that one accident that's only a five-thousand-dollar accident if you have any type of a larger accident you can see how quickly that can escalate to very large sums of money so it always makes sense to be preventative in a situation like this and you know stop it before any of this stuff ever comes up OSHA as you see estimates up for about every dollar you invest in workplace safety and health that you see about a four to six dollar return and that's that's kind of exemplified in the slide we saw previously where you have such a large multiplier effect when you have any type of an accident so the top ten benefits we see babe besides just monies we have decreased work-related accident absenteeism obviously somebody gets hurt they miss work that's a burden on the other workers as well as lost productivity decreased workers compensation costs as we saw before decreased health care costs again back to the insurance premium decrease crap ways that's kind of one of those hidden type costs bringing a new worker doesn't know what they're doing maybe they make some bad parts that's good product you're thrown in the trash that's another cost that kind of lends its way back to the efficiency increased quality by keeping the same workers and not having to train newer ones higher productivity better brand image by not having a plant that has lost time accidents all the time obviously makes them look better the morality ously goes up anytime there's a serious type accident obviously the morale of the other workers is going to go down an increased employee retention rates employees obviously would like to work in a place so they don't have to worry about any type of injuries so who is really responsible for the safety in the end we all are the manufacturer is responsible for the design and construction of the machine in a safe manner the instruction manual the operator manual and the maintenance manual all need to reflect those safety devices how they need to be taken care of and how they should be implemented correctly the user is responsible for the overall safety of the machine as they operate it the maintenance inspection procedures which need to be done most most plants have that done every shift there the training of these people is also necessary layout installation testing start up again set up operation maintenance and then the operator must comply with these instructions that have been laid out for them so in the United States and Canada in north america the responsibilities and legal implications most people think well isn't the manufacturer of this machine the one who is ultimately responsible for the safety and safeguards on that machine and really that's not exactly true in the united states and canada once that machine comes into your plant and you sign off on it the manufacturer is basically out of the loop now they can't prove that you didn't make any differences to the air any changes to that machine once they left so as long as you signed off saying that it was safe to your specifications they're pretty much off the hook at this point and now it's your problem so anytime you're looking at placing in order for new equipment it's important to make sure that all of these safeguards are put into place before you accept the machinery again this keeps keeps you covered and puts the onus on them to have this done correctly before they get the machine to you again after the machine has been signed off on it's now yours and the manufacturers pretty much out of the loop so what are the legal implications of having an unsafe work environment well if there is an accident there will almost always be an investigation depending on the severity of the accident could result in serious legal consequences if negligence can be proven so if you're in a company and your management becomes aware that there is an unguarded danger point or generally an unsafe condition on a machine what's the best thing that you can do you can call the state's professional clearly identify the hazard get a safety solution and use the here our core approach which we'll see on the next slide designing it out which is the best way to do it actually see the next slide eliminating this hazard by design is obviously the best way we can go about this taking the hazard completely away and making it now not even there anymore is the best way we can handle that the next step if we can't design out of machine would be to control the access to the exposures by safeguarding this would be hard guarding aop DS Lite curtains roto scans interlock switches anything like that that can help us control access to the dangerous point the next one would be to provide safety measures like awareness barriers signals you know the you saw have seen the yellow caution tape on the floor signs warning of pinch points things like that there should be administrative controls which would be training procedures and a personal protective equipment as you can see by the arrow we have sewing here we go in order of how effective they actually are so eliminated completely out obviously is the best way PPE and procedures and training the least effective so how do we know when we have an unsafe condition well a general quick general way to check this on any type of machinery is it needs to be sized that as such a person cannot reach and this where we use the adapt the acronym auto around under through or over if you can reach around the guarding under the starting through the guarding or over the guarding assuming there is guarding and reached a dangerous point to access the hazard then we have a hazardous situation and we need safeguards put in place so how do we find what the right type of protection system is once we do know we have this unsafe condition well the first thing that would be the best way to go around this would be a risk assessment of that application that would help us find the necessary safety level we need we'll go over safety levels and some of these in a future webinar will talk about safety integration levels performance levels and safety categories and kind of how they intertwine with each other so we find what are the dangerous movements is that a spindle is it a press coming down is it a pinch point out of gear what can happen during the normal operation of the machine that could expose you to those hazards and you also need to think of what can occur during the setup and maintenance this is something that a lot of people kind of look past when they're looking at the safety of a machine that you think about it how it's going to work when the machine is running but you need to also be very cognizant of how this machine is worked on as far as a maintenance a lot of times there are certain parts of the machine that are disabled or bypassed when you go into the setup and maintenance modes that needs to be taken care of when you do this risk assessment it needs to be taken account for account house so once we know what our hazard is and where it is then we have to decide what we're going to do to to alleviate that hazard well there's a couple different ways we can go you've got Spencer's sheet metal for a general reduction of danger x axis we've all seen sure robotic cells with fences completely around the machine or seen casting cells that are completely enclosed in fencing with interlocked doors things of that nature if that doesn't work then maybe we have to go with some type of an AOP D which would be a single or multiple beam safety device like curtain laser scanner position switches safety mats then we have to have something that's going to evaluate all of these safety devices so safety relay safety controller or a programmable safety controller we then have to take into account the reaction of the actuators as contactors valves drives it's not always complete when you put a full safety system on to a machine that doesn't necessarily always fix the problem you need to look at how these valves are going to how they're going to be affected by taking power away from them basically so if you have a machine that's got single solenoid valves on it you remove power that doesn't necessarily stop motion that just reverses function so a lot of these things need to be taken into account when you're doing a full survey of the machine so there's really three main types of hazard protection we're going to be dealing with point of operation guarding which is when you have an operator who is using apart maybe in a small process machine something like that where they're going to be getting their hands very near to the danger point and there's different ways for us to guard that as well as a danger zone guarding which is where you're trying to protect a person from coming into an area and we have access guarding we were basically trying to stop anybody from going into there without tripping the thing so the first being an example of a point of operation guard here we have a small process machine a little press light curtain small resolution on the light curtains fingertip control that way anybody gets into this machine stops press stop cycling a hard guard version of something similar to that would be this very small openings can't get your fingers in far enough to get to the dangerous point example of an access card would be maybe using a multi-beam multiple light beam device here we see a to beam version being used for a perimeter guard and then we have a three-beam also be used here as a perimeter guard both of these circumstances could also use hard guarding if necessary with interlocked doors and then we have well here's a real-life picture of a access carding example we have a three-beam multiple light beam device on both sides of the starting access operator walks in their places the part down walks back out resets the machine starts back up so this is an application where hard guarding probably would not work because you have to be opening and shutting the door every time you went to the place and remove apart so we do hard guarding on the sides and then we do a light barrier where the access point is example here of a roto scan type application where we're doing a danger zone this is kind of unique whereas that danger zone is going to be a moving point we have this big gantry that's moving back and forth on these rails it's not really possible to hard guard this because it is moving there's really no place to put any type of a light curtain so in this type of a situation we have a roto scan you can't really see it great in that picture but you have a roto scan they're scanning for a distance in front of this I'm assuming there's also one on the back side of this machine so as machine moves the dangerous area to stay out of moves along with it and if somebody were to walk in front or behind this machine we'd get a signal to stop the machine safely so when we move on to more of the technical type topics these are kind of the go-to standards we're going to be referencing a lot OSHA obviously everybody knows about OSHA in Canada we have CSA which is kind of a guideline more than it is a law each province has their own laws but I think they use CSA pretty much as the baseline that they use to make their standards and then we also go with the European norms this is a good one to look at because in the future most of these safety was the safety regulations are all going to be standardized and they're most likely going to be going towards closer to the European norms and then what we do here at OSHA and we can see that and some future webinars will do you'll see the difference when we do just something simple like a safety safety distance calculation how different it turns out to be if we go by an CRI a or if we go by European norms or if we go by OSHA they all come out to a different distance as far as electrical we have nfpa we have the ante RI a CSA again these aren't laws but these are what most of the laws are based on so some of the future topics will be seeing identifying hazards performance requirements so in thi type of atopic we'll be looking a little bit closer again today was just a brief overview we'll get more in depth on the future webinars so we'll talk a little bit more about identifying hazards and how to figure out what the performance requirement is to safeguard that hazard we'll look at safe distance calculation and the effects of resolution and mounting has on that depending on hard guarding or light curtains your resolution in other words the spacing between the beams how big of a part that plays in your safe distance calculation as well as the way that you mount them how high they are off the floor how tall the actual safe guarded area is I will look at specific requirements for muting blanking and initiations in regards to light curtains putting a light curtain on a machine with muting blanking or initiation there are a lot of certain considerations that need to be made especially in the mounting and the wiring of these these devices to make them conform we'll look at the pros and cons of hard guarding versus kop DS or or opto-electronic guarding such as light curtains laser scanners multiple light beam devices specific considerations for power oppresses power presses have a lot of their own guidelines separate from anything else because it is a different type of machine and it is very dangerous so we'll look at some of those considerations and future webinars will look at different application areas for light beams versus like curtains what is the type of an instance where a light curtain would work when with a multiple beam work sometimes there are instances where both work and we'll kind of go through that and help you figure out what is the best thing you're going to need for that type of a hazard EDM and restart functions will go through how those work why we need them and how to use them correctly look at the differences between type 2 and type 4 devices in theory as well as in practice and what you need to know before you make that type of a decision on what type of a device you need to use we'll look at estop circuits and the proper way to implement any stock circuit we see a lot of you stop circuits in the field that are not being used correctly so this is something that's kind of important we need to get down because the e-stop is not like a liker and it's not restricting a dangerous movement it's not restricting access this is in in truth and emergency stop everything needs to stop and then we'll look at some of the common mistakes that we see in the field a lot a ways that we can make sure and avoid those so those will be some of the future topics that will be covering again anything you guys have that is specific and you'd like to see maybe something you have questions on something you've seen in the field before you'd like to explain a little better feel free to email myself for marking and if it's something that we think is pretty good we'll do a webinar on it those are this is a I don't know if I introduce myself I'm Chris halsted on the controls engineer here at lloyds electronic with me is marked he is the product manager for the safety products again you can email either one of us there we are or call with any safety questions you have if you have any ideas for future topics be sure and let us know anybody on here who is a distributor or or a sales person you can be sure and pass this on to any of your customers if you'd like again this is not we're not pushing products on anybody we're not going to be discussing our products only we're just going to be looking at theory and the practice of safety as far as technical aspects of a mounting wiring safety distances stuff like that so it's going to be a lot of good information very nonspecific as far as which products so anybody you can think of it maybe benefit from this be sure to let them know