Machine safety and degrading component reliability

Is your machine downtime sometimes a surprise? Did a component in a safety circuit fail because it simply wore out and nobody knew it was about to fail? Well, maybe help has just arrived. Has anyone heard about EN ISO 13849-1; 2008? See "4 ways to reduce surprise downtime."

07/14/2011


JB Titus, CFSEIs your machine downtime sometimes a surprise? Did a component in a safety circuit fail because it simply wore out and nobody knew it was about to fail? Well, maybe help has just arrived. Has anyone heard about EN ISO 13849-1; 2008?

   This new standard (Safety of machinery, Safety-related parts of control systems) has arrived and the Machinery Directive in Europe has established its effective date as Jan. 1, 2012. Since the US is part of the ISO (International Standards Organization) many companies in the US are making plans to or have already adopted this new standard. In my opinion, 13849-1 improves machine safety because it moves machine safety from qualitative Categories to quantitative Performance levels. Compliance requirements in this new standard will now address all of the components in a safety circuit while determining that circuit’s Performance Level. As such, the expected life of a component is determined and documented relative to its expected number of cycles during machine operation. Therefore, the weak links can be identified and flagged early on during the design stage. This is particularly important for those components that are electro/mechanical, such as contactors or safety relays, and have moving parts or points that wear out over time. This wearing out over time is what many people refer to as “degrading component reliability”.

   OK, great! Does anyone have an idea with this information how to reduce the surprise downtime (and possible hazard) related to this type of component failure?

4 ways to reduce surprise downtime

   Several thoughts I have are as follows:

1.)   Identify and document these components in your risk assessment for the machine.

2.)   Add these components to your preventive maintenance plan.

3.)   Plan for routine machine maintenance to replace these components before their expected failure.

4.)   Update your risk assessment for the machine.

   I have barely touched on the comprehensive approach for Functional Safety addressed by EN ISO 13849-1; 2008. Several companies and consultants offer two and three day classes on the new compliance requirements embedded in this new standard. In my opinion, to fully understand these compliance requirements you should consider contacting these sources and consider enrolling in one of their classes.

   Your comments or suggestion are always welcome so please let us know your thoughts. Submit your ideas, experiences, and challenges on this subject in the comments section below. Click on the following text if you don't see a comments box, then scroll down: Machine Safety & Degrading Component Reliability.

   Did you see the Safety Integration Webcast?

   Related articles:

EN ISO 13849-1; 2008 - Are We Ready? - Part 2

Trouble Implementing ISO 13849-1; 2006 per the European Machinery Directive

B10s at work for machine guarding

Contact: www.jbtitus.com for “Solutions for Machine Safety”.



The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Doubling down on digital manufacturing; Data driving predictive maintenance; Electric motors and generators; Rewarding operational improvement
2017 Lubrication Guide; Software tools; Microgrids and energy strategies; Use robots effectively
The cloud, mobility, and remote operations; SCADA and contextual mobility; Custom UPS empowering a secure pipeline
Infrastructure for natural gas expansion; Artificial lift methods; Disruptive technology and fugitive gas emissions
Mobility as the means to offshore innovation; Preventing another Deepwater Horizon; ROVs as subsea robots; SCADA and the radio spectrum
Power system design for high-performance buildings; mitigating arc flash hazards
Research team developing Tesla coil designs; Implementing wireless process sensing
Commissioning electrical systems; Designing emergency and standby generator systems; Paralleling switchgear generator systems

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
The maintenance journey has been a long, slow trek for most manufacturers and has gone from preventive maintenance to predictive maintenance.
Featured articles highlight technologies that enable the Industrial Internet of Things, IIoT-related products and strategies to get data more easily to the user.
This digital report will explore several aspects of how IIoT will transform manufacturing in the coming years.
Maintenance Manager; California Oils Corp.
Associate, Electrical Engineering; Wood Harbinger
Control Systems Engineer; Robert Bosch Corp.
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
click me