Machine Safety
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Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis, operating efficiencies and cost savings, as well as all relevant safety standards, such as those from NFPA, ANSI, RIA, IEC, ISO and OSHA. About
Machine Safety: Functional safety and the steps to be compliant in the U.S.
April 17, 2012
Who has the steps identified for anyone considering moving their machine safety compliance to functional safety for their organization? Let’s assume for this discussion that functional safety means being compliant with EN ISO 13849-1. » more
( 1 Comment )
April 17, 2012
Who has the steps identified for anyone considering moving their machine safety compliance to functional safety for their organization? Let’s assume for this discussion that functional safety means being compliant with EN ISO 13849-1. » more
( 1 Comment )
Machine Guarding: Trouble shooting old systems is doomed with iPad skills
April 17, 2012
Do today's new hires have what it takes? Over the past 10 years machine safety has experienced probably the greatest transformation since the advent of machine control technology, which sets the stage for an organizational skills gap discussion. Are the skilled trades persons entering industry over the past ten years equipped to evaluate and trouble shoot... » more
( 2 Comments )
April 17, 2012
Do today's new hires have what it takes? Over the past 10 years machine safety has experienced probably the greatest transformation since the advent of machine control technology, which sets the stage for an organizational skills gap discussion. Are the skilled trades persons entering industry over the past ten years equipped to evaluate and trouble shoot... » more
( 2 Comments )
Machine Safety: The missing ah-ha for plant management
March 29, 2012
Isn’t the machine a hazard as well as the individual hazards on a machine? Last week I blogged about risk assessments, the mitigation process, and how the new methodologies have migrated from qualitative to quantitative approaches. Since designers have engineering tools to design out hazards. Managers need reliable tools to designate an individual hazard... » more
( No Comments )
March 29, 2012
Isn’t the machine a hazard as well as the individual hazards on a machine? Last week I blogged about risk assessments, the mitigation process, and how the new methodologies have migrated from qualitative to quantitative approaches. Since designers have engineering tools to design out hazards. Managers need reliable tools to designate an individual hazard... » more
( No Comments )
Machine Safety: Does it matter, the Aggregate Hazard Level for a machine?
March 23, 2012
When conducting a risk assessment of the machine’s individual identified hazards does the safety level of the complete machine or system matter? Does anyone have a solution for determining the aggregate level of an entire machine? Does anybody care? » more
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March 23, 2012
When conducting a risk assessment of the machine’s individual identified hazards does the safety level of the complete machine or system matter? Does anyone have a solution for determining the aggregate level of an entire machine? Does anybody care? » more
( No Comments )
Machine Safety: Are you staying on target?
March 15, 2012
Is changing my machine safety strategy necessary? What if your safety target has shifted? Have there been evolutional changes to industrial safety but your safety culture is mired in the past? Are there newer machine guarding solutions that are more cost effective? To stay on target consider updates to your safety culture and your machine guarding solutions... » more
( No Comments )
March 15, 2012
Is changing my machine safety strategy necessary? What if your safety target has shifted? Have there been evolutional changes to industrial safety but your safety culture is mired in the past? Are there newer machine guarding solutions that are more cost effective? To stay on target consider updates to your safety culture and your machine guarding solutions... » more
( No Comments )
Machine Safety: System degradation and incidence of injury
February 17, 2012
Are older hardwired safety systems less safe than newer integrated safety systems? (See table.) Since 2002 when integrated safety automation was introduced for machine safety, a growing awareness has emerged questioning the effectiveness over time of a hardwired / hardware safety system versus an integrated safety system. What is the ultimate effectiveness... » more
( No Comments )
February 17, 2012
Are older hardwired safety systems less safe than newer integrated safety systems? (See table.) Since 2002 when integrated safety automation was introduced for machine safety, a growing awareness has emerged questioning the effectiveness over time of a hardwired / hardware safety system versus an integrated safety system. What is the ultimate effectiveness... » more
( No Comments )
Machine Safety: ISO 13849-1 compliance is mandatory for robot applications, ANSI/RIA/ISO 10218-1&2: 2011
February 07, 2012
Are you aware that our consensus standard for robots (RIA 15.06) has changed and now calls out normative compliance requirements to ISO 13849-1: 2006? How many machine safety domestic standards have made this transition? Does anybody know? (See related link added June 4.) » more
( No Comments )
February 07, 2012
Are you aware that our consensus standard for robots (RIA 15.06) has changed and now calls out normative compliance requirements to ISO 13849-1: 2006? How many machine safety domestic standards have made this transition? Does anybody know? (See related link added June 4.) » more
( No Comments )
Machine Safety: NFPA 70E and international requirements
January 30, 2012
Machine Safety has several different focused areas of potential hazards. One of the areas getting a lot of attention is Arc Flash and NFPA 70E. A recent article published by Control Engineering earlier this month had some startling results. An alarming 72% of respondents (302) “always” plus “mostly” regularly violate NFPA 70E while working on control... » more
( 2 Comments )
January 30, 2012
Machine Safety has several different focused areas of potential hazards. One of the areas getting a lot of attention is Arc Flash and NFPA 70E. A recent article published by Control Engineering earlier this month had some startling results. An alarming 72% of respondents (302) “always” plus “mostly” regularly violate NFPA 70E while working on control... » more
( 2 Comments )
Machine Safety: Without an injury, OSHA issues citations for more than $1 million
January 23, 2012
Whoa, OSHA issues fines for $1,013,000. following a complaint filed by a worker. OSHA investigated the manufacturer and discovered 13 Serious and 17 Willful violations of Regulations. Was this Company just waiting to be caught in violation or were these violations a result of their safety culture. You decide! » more
( 1 Comment )
January 23, 2012
Whoa, OSHA issues fines for $1,013,000. following a complaint filed by a worker. OSHA investigated the manufacturer and discovered 13 Serious and 17 Willful violations of Regulations. Was this Company just waiting to be caught in violation or were these violations a result of their safety culture. You decide! » more
( 1 Comment )
Machine Safety: How safe is safe enough?
January 12, 2012
In machine guarding, how safe is safe enough? Over my 40 years in industry I’ve heard this comment many times. Is this attitude driven by “safety culture” or is it just a product of qualitative risk management? Is this why risk management for machine guarding and functional safety is advancing globally to quantitatively derived engineering and validation? » more
( No Comments )
January 12, 2012
In machine guarding, how safe is safe enough? Over my 40 years in industry I’ve heard this comment many times. Is this attitude driven by “safety culture” or is it just a product of qualitative risk management? Is this why risk management for machine guarding and functional safety is advancing globally to quantitatively derived engineering and validation? » more
( No Comments )
EN ISO 13849-1, the quantitative approach to machine safety begins with a qualitative process
January 06, 2012
EN ISO 13849-1 has now been fully in force since Jan. 1, 2012, without exception and EN 954 has fully been withdrawn. We’ve heard for four years or more that this change in direction equates to a paradigm shift for industry because it in part moves hazard level determination and mitigation from a qualitative process to a quantitative process. There’s more... » more
( No Comments )
January 06, 2012
EN ISO 13849-1 has now been fully in force since Jan. 1, 2012, without exception and EN 954 has fully been withdrawn. We’ve heard for four years or more that this change in direction equates to a paradigm shift for industry because it in part moves hazard level determination and mitigation from a qualitative process to a quantitative process. There’s more... » more
( No Comments )
Machine Safety: The myths of safety cultures
January 05, 2012
Every organization at some point in time has held a myth about machine safety. Here are six machine safety myths. What’s yours? Leave a comment. » more
( No Comments )
January 05, 2012
Every organization at some point in time has held a myth about machine safety. Here are six machine safety myths. What’s yours? Leave a comment. » more
( No Comments )
Machine Safety: Does adding a hard guard always make your machine safer?
December 29, 2011
Machine guarding is sometimes approached with the methodology that says lets first add a hard guard to protect the operator from the hazard. Does this always mitigate the hazard, reduce the hazard to an acceptable level, or achieve “safe enough”? » more
( No Comments )
December 29, 2011
Machine guarding is sometimes approached with the methodology that says lets first add a hard guard to protect the operator from the hazard. Does this always mitigate the hazard, reduce the hazard to an acceptable level, or achieve “safe enough”? » more
( No Comments )
Machinery Directive In 4 Days Drops EN 954 and EN ISO 13849-1 Is Fully In Force: What’s Your Impact?
December 27, 2011
In Europe on Jan. 1, 2012 the qualitative process (EN 954) of machine safety hazard identification (B, 1, 2, 3, and 4) and mitigation disappears and the quantitative process (EN ISO 13849-1) is fully in force with its compliance requirements of Performance Level (a, b, c, d, and e). The Category system is officially put to rest and hence forth all safety... » more
( No Comments )
December 27, 2011
In Europe on Jan. 1, 2012 the qualitative process (EN 954) of machine safety hazard identification (B, 1, 2, 3, and 4) and mitigation disappears and the quantitative process (EN ISO 13849-1) is fully in force with its compliance requirements of Performance Level (a, b, c, d, and e). The Category system is officially put to rest and hence forth all safety... » more
( No Comments )
Machine Safety: Are you using planning and execution tools?
December 09, 2011
Machine guarding has clearly entered the technology world with integrated safety systems. But, are you still using 1970s approaches for planning and executing? Scotty didn’t beam colleagues to the Starship Enterprise via Hertz Rent-a-Car! » more
( No Comments )
December 09, 2011
Machine guarding has clearly entered the technology world with integrated safety systems. But, are you still using 1970s approaches for planning and executing? Scotty didn’t beam colleagues to the Starship Enterprise via Hertz Rent-a-Car! » more
( No Comments )
Machine safety and integrated safety systems
December 05, 2011
Integrated safety systems are proven to improve productivity, safety, and the bottom line. Really? So, what’s holding back the tsunami of industry picking up the pace to apply integrated safety systems across manufacturing? » more
( No Comments )
December 05, 2011
Integrated safety systems are proven to improve productivity, safety, and the bottom line. Really? So, what’s holding back the tsunami of industry picking up the pace to apply integrated safety systems across manufacturing? » more
( No Comments )
Machine Safety Culture: Compliance versus cooperation driven
November 30, 2011
Employee safety compliance is a blend of hard physical restraints or barriers and a desire to follow a set of safety behaviors. But, compliance is interpreted by most as meeting the bare minimums. And, if employees don’t choose to accept or behave in the role “another” has found for them, they don’t have to play it. If so, how does a company develop or... » more
( No Comments )
November 30, 2011
Employee safety compliance is a blend of hard physical restraints or barriers and a desire to follow a set of safety behaviors. But, compliance is interpreted by most as meeting the bare minimums. And, if employees don’t choose to accept or behave in the role “another” has found for them, they don’t have to play it. If so, how does a company develop or... » more
( No Comments )
Machine Guarding: Do I need to follow codes and regulations like NFPA?
November 22, 2011
What is the purpose of so many codes and regulations? I work in panels all the time. Sure, I take risks every day but do “I” need regulations to keep “me” safe? Bah humbug on the regulations. I know what I’m doing! (Leave your comment: Do you think you're safe without PPE in some control panels?) » more
( No Comments )
November 22, 2011
What is the purpose of so many codes and regulations? I work in panels all the time. Sure, I take risks every day but do “I” need regulations to keep “me” safe? Bah humbug on the regulations. I know what I’m doing! (Leave your comment: Do you think you're safe without PPE in some control panels?) » more
( No Comments )
Machine Guarding: Tolerable vs residual risk
November 11, 2011
Why do so many colleagues in manufacturing choose to avoid the terms – tolerable risk and residual risk? If there’s one thing “integrated safety systems” and requirements for risk assessments have brought to the industrial forefront over the past ten years – it’s risk awareness. It’s now “OK” in conversation and correspondence within companies to use words... » more
( No Comments )
November 11, 2011
Why do so many colleagues in manufacturing choose to avoid the terms – tolerable risk and residual risk? If there’s one thing “integrated safety systems” and requirements for risk assessments have brought to the industrial forefront over the past ten years – it’s risk awareness. It’s now “OK” in conversation and correspondence within companies to use words... » more
( No Comments )
Machine guarding: Category 4 versus reliability
November 03, 2011
When is a Category 4 solution ineffective in a machine guarding application? Is your machine safety risk assessment looking at the right things? Is this your accident waiting to happen? Consider this example. » more
( No Comments )
November 03, 2011
When is a Category 4 solution ineffective in a machine guarding application? Is your machine safety risk assessment looking at the right things? Is this your accident waiting to happen? Consider this example. » more
( No Comments )
Machine guarding and economic value: Wired safety versus safety automation
October 31, 2011
Over the past 10 years machine safety has experienced probably the greatest transformation since the advent of machine control technology. In my opinion, the recent adoption of “safety automation” has outpaced the original adoption of PLC technology in the early 1970’s. It was in the early 1970’s that machine safety was mandated by industry standards to be... » more
( 1 Comment )
October 31, 2011
Over the past 10 years machine safety has experienced probably the greatest transformation since the advent of machine control technology. In my opinion, the recent adoption of “safety automation” has outpaced the original adoption of PLC technology in the early 1970’s. It was in the early 1970’s that machine safety was mandated by industry standards to be... » more
( 1 Comment )
Machine guarding and the hierarchy of measures for hazard mitigation
October 25, 2011
Do you know the five levels of hazard mitigation? Machine guarding isn’t completed task that’s checked off a list. Eliminate, isolate, add engineering, implement controls, and use PPE, then repeat. » more
( No Comments )
October 25, 2011
Do you know the five levels of hazard mitigation? Machine guarding isn’t completed task that’s checked off a list. Eliminate, isolate, add engineering, implement controls, and use PPE, then repeat. » more
( No Comments )
ISO 13849-1 Machine Guarding Adoption, Part 4 - safety standard merger
September 24, 2011
Adopting EN ISO 13849-1 by Dec. 31, 2011 has been taking a lot of attention this year particularly for manufacturers of machinery and global end users. Guess what? The IEC (International Electrotechnical Commission) world and the ISO (International Standardization Organization) world are voting to merge EN ISO 13849-1 and IEC 62061. Yikes – when will... » more
( No Comments )
September 24, 2011
Adopting EN ISO 13849-1 by Dec. 31, 2011 has been taking a lot of attention this year particularly for manufacturers of machinery and global end users. Guess what? The IEC (International Electrotechnical Commission) world and the ISO (International Standardization Organization) world are voting to merge EN ISO 13849-1 and IEC 62061. Yikes – when will... » more
( No Comments )
ISO 13849-1 Machine Guarding adoption, Part 3
September 01, 2011
What is your plan to comply with the ISO 13849-1 Machine Guarding standard? By now you’ve attended seminars, read white papers and magazine articles, heard from colleagues, or even read some of these blogs on this subject. So what? We don’t legislate compliance in the US. Instead, we have consensus standards. » more
( 3 Comments )
September 01, 2011
What is your plan to comply with the ISO 13849-1 Machine Guarding standard? By now you’ve attended seminars, read white papers and magazine articles, heard from colleagues, or even read some of these blogs on this subject. So what? We don’t legislate compliance in the US. Instead, we have consensus standards. » more
( 3 Comments )
ISO 13849-1 Machine Guarding adoption, part 2
August 24, 2011
The scope statement in the machine guarding standard reads, “This part of ISO 13849 provides safety requirements and guidance on the principles for the design and integration of safety-related parts of control systems (SRP/CS), including the design of software. For these parts of SRP/CS, it specifies characteristics that include the performance level... » more
( No Comments )
August 24, 2011
The scope statement in the machine guarding standard reads, “This part of ISO 13849 provides safety requirements and guidance on the principles for the design and integration of safety-related parts of control systems (SRP/CS), including the design of software. For these parts of SRP/CS, it specifies characteristics that include the performance level... » more
( No Comments )
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