Machine guarding and economic value: Wired safety versus safety automation

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 “hard wired.” At this time, PLC technology had just been introduced, and its reliability paled in contrast to the robust PLC reliability of today. See graph illustrated below.

11/01/2011


Machine safety has experience probably the greatest transformation over the past 10 years 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 1970s. It was in the early 1970s that machine safety was mandated by industry standards to be “hard wired.” At this time PLC technology had just been introduced and its reliability paled in contrast to the robust PLC reliability of today. Just take a quick glance at the conceptual graph illustrated below.

Graph explaining the growth of general automation versus machine safety technology along with downtime. Courtesy: J.B. Titus 

I experienced the introduction of automation technology lead by PLCs as a young engineer in an automotive plant. After a slow start, automation technology took off like a rocket experiencing wide spread adoption and application to machine control. The advantages of diagnostics reduced wiring, increased machine up-time, reduced panel space, easier trouble shooting, etc. drove acceptance as research and development drove technological improvements and inherent reliability. At the same time, however, machine safety was required to be hard wired and could not enjoy these advantages or technological improvements.

JB Titus, CFSEIn my opinion, this created a safety layer in the machine control architecture interfacing the safety related electromechanical components to the machine control automation technology. The unintended consequences resulted in a rather stagnant level of technology innovation for the safety layer in comparison to the automation technology. This gap of technology helped drive a new metric called “unplanned downtime.” Plant operation personnel became used to the diagnostics and other advantages of the automation technology and conversely became frustrated by the lack of diagnostics, intermittent downtimes, and other disadvantages of the safety layer. Thusly, many of us experienced occasions where “quick fixes” were made to get machines back into production to meet schedule demands.

To make a long story short, folks in my era have experienced the changing landscape of machine control to once again see the unified machine control architecture of “integrated automation with safety” in innovative technology. Machine safety can once again be designed in vs an after-thought. Of course, direct wiring of safety components is still a viable option. However, for larger more complicated machines integrated safety is now available. Most importantly the economic values of increased productivity can drive increased profits which in turn can provide a competitive advantage.

What experiences have you had along this changing landscape evolution?

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 Guarding & Economic Value – wired safety vs safety automation

Did you see the Safety Integration Webcast?

Related articles:

Cost Savings Opportunities in Machine Safety

Machine Safety Pays

Risk assessment - A best practice for sustainable performance

Machine safety pays off

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.
Pipe fabrication and IIoT; 2017 Product of the Year finalists
The future of electrical safety; Four keys to RPM success; Picking the right weld fume option
A new approach to the Skills Gap; Community colleges may hold the key for manufacturing; 2017 Engineering Leaders Under 40
Control room technology innovation; Practical approaches to corrosion protection; Pipeline regulator revises quality programs
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
Power system design for high-performance buildings; mitigating arc flash hazards
VFDs improving motion control applications; Powering automation and IIoT wirelessly; Connecting the dots
Natural gas engines; New applications for fuel cells; Large engines become more efficient; Extending boiler life

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.
This digital report explains how plant engineers and subject matter experts (SME) need support for time series data and its many challenges.
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