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COVER STORY ADVERTISEMENT FEATURE OT BE AN AFTERTHOUGHT
operator’s possession, ensuring that the machine cannot be restarted until the key is returned, thereby preventing accidental restarts. This approach is a modern alternative to traditional Lock Out Tag Out (LOTO) procedures, especially for those short-term interventions, providing both enhanced safety and operational flexibility.
• Enhanced Operational Efficiency: By integrating safety into the design process, machines can be made safer without compromising efficiency. For example, safety interlocks and control systems can be designed to allow safe operation and access to certain parts of the machine while it is still running. This ensures that maintenance tasks, such as loading consumables like cardboard packaging, can be carried out without stopping the entire production line, thus minimizing downtime and maintaining productivity. Importantly, the design needs to consider foreseeable misuse. Through intelligent safe design that allows the operator to interact with the machine safely, you reduce the likelihood of operators attempting to manipulate safety systems to gain access – for example, by removing the actuator of a safety interlock. Such manipulation typically results in the complete absence of safety measures, which can lead to dangerous situations. By anticipating these risks and designing machinery that accommodates necessary interactions, we can maintain both safety and efficiency.
• Cost Savings: Addressing safety early in the design process can also lead to significant cost
savings. Retrofitting safety features after a machine has been built or, worse, after an incident has occurred, can be expensive and disruptive. By considering safety from the beginning, manufacturers can avoid these costs and ensure that their machines are both safe and cost-effective.
ADAPTING TO NEW OPERATIONAL REALITIES The need for continuous operation and real-time data has brought about significant changes in how safety is approached in machinery design. New technologies and methodologies are being developed to ensure that machines can operate safely, even under demanding conditions. • Failsafe Overrides: In some cases, it is necessary to allow operators to override certain safety features to perform essential tasks while the machine is still running. For example, when adjusting tracking on a printing machine, it may not be practical or efficient to stop the entire machine. In these situations, failsafe overrides can be implemented to allow access while still maintaining a safe operational environment. These overrides are designed with strict safety protocols to ensure that they do not introduce new risks. The all-too-common method of providing the operator with a spare ‘actuator key’ is not a suitable method.
• Real-Time Data and Safety: The demand for real-time data in modern manufacturing processes has significantly increased over the past few years. In addition to ensuring safe operation, modern safety systems provide valuable insights through the data they collect. For example, tracking the number of times each individual access point is opened during a shift can offer critical information about the machinery’s reliability. Frequent access may indicate underlying issues, such as recurrent faults or the need for maintenance, which might otherwise go unnoticed. By analysing this data, operators can proactively address potential problems, leading to improved machinery reliability and reduced downtime. Thus, the integration of real-time data with safety systems not only enhances safety but also contributes to more informed decision-making and overall operational efficiency.
ENSURING SAFETY In the evolving landscape of industrial machinery design, ensuring safety without compromising efficiency is a complex challenge. This is where partnering with experienced safety solution providers like Euchner can make a significant
difference. Euchner offers a range of advanced safety products, such as the CKS2 key system and CTS Interlock, that are designed to meet the highest safety standards while integrating seamlessly into modern machinery.
“The need for
continuous operation and real-time data has brought about significant changes in how safety is approached in
machinery design” By collaborating with Euchner, designers can
leverage their expertise in safety technology to develop systems that not only protect operators but also enhance operational efficiency. Euchner’s solutions are tailored to anticipate and mitigate potential risks, ensuring that safety is built into the design from the very beginning. With Euchner’s support, designers can create machinery that meets regulatory requirements, prevents unsafe practices, and provides real-time data for better decision- making, ultimately leading to safer and more reliable production environments.
Euchner
T: 01142 560123
sales@euchner.co.uk www.euchner.co.uk
JULY/AUGUST 2024 DESIGN SOLUTIONS 13
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