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HAZARDOUS AREAS & SAFETY PROMOTING SAFETY FROM THE GROUND UP


Campari Group is improving safety worldwide with the help of OMRON Safety Services


T


hanks to the support of OMRON Safety Services, Campari has recently revolutionised its global safety


programmes. Starting with the company's plant in Novi Ligure, Italy, this systems overhaul has enabled the leading spirits manufacturer to improve safety management of machinery and processes, as well as make strides in the field of governance.


Continued expansion into the global market and the resulting technological challenges have led the Campari Group – the sixth largest in the global spirits sector and with a portfolio of 50 brands – to completely rethink its safety policies. The company wanted to transform health and safety in the workplace by moving from a purely procedural to a more pragmatic approach that put operators themselves at the forefront of the process and resulted in guidelines that would allow safe but flexible working.


To accompany them on this journey, Campari chose OMRON. Their Safety Services division's proven track record in combining technology with ever-evolving skills, as well as their ability to guarantee the level of geographical availability needed to deploy the new systems uniformly across all 14 of the company's locations on three continents, made them a natural choice of partner.


The Campari Group's transformation project stemmed from a desire to change the culture within the organisation. "We wanted a different approach to safety, and that included attitudes toward it," explained the managers at the Novi Ligure plant, which was chosen to pilot the project before it was rolled out worldwide. "We wanted to get people involved from the initial


development stages through to best practices, both to ensure as little impact as possible on day-to-day work and to be able to properly train them and make it easier to pass on the right information about safety. Doing this internally in a structured way is something else, which is why we worked with OMRON to do it in a way that was new and innovative, but still as standardised as possible so that it can be shared across all the other plants." Specifically, Campari wanted a dedicated Global Program Manager to handle everything related to planning and progress updates, large-scale training to assist with cultural change and long-term protection of existing investments. This Global Program Manager would also need to oversee the development of technical specifications for the most widespread activities within the group (such as pal, depal, filling machines, labeling machines) and the implementation of tools and services with the right level of reassurance when purchasing new production machines and equipment. The first step was to prepare an initial report, which was based on a visual inspection of the machines and a discussion with operators and managers to understand how everything worked in practice. In particular, an assessment was carried out on machines requiring CE marking, their safety and suitability for use, any hazards and how often they occurred, and priority risks. This helped provide a general overview of possible risk mitigation measures so that initial implementation plans could be drawn up. Appropriate documentation with functional specifications (mechanical, electrical,


pneumatic and hydraulic specifications and associated diagrams) then needed to be developed; safety-related control systems and performance levels as per the EN ISO 13849-1 standard had to be analysed; technical documentation needed updating; any necessary components and equipment had to be procured; and the design solution needed to be installed. In terms of validation, verification and implementation, an assessment was carried out in line with the usage guidelines for the work equipment before the machines were put back into service. Once this stage was complete, tests were carried out on the safety features to make sure that they were working properly. Safety devices and fixed covers were also checked to ensure that they were properly installed (for example by checking safety distances). All of the risk assessment steps were also reviewed to see if there were any changes to the limits of the machinery, any new hazards (or hazardous situations) and whether any additional protective measures were needed.


Campari's requirements were met through a tailor-made solution, every aspect of which was customised from engineering onward. In its role as technology provider, OMRON analysed the existing state of affairs irrespective of the type of technology installed on the machines or systems. In addition to automation, the assessments focused on the impact that the newly implemented safety systems could have on efficiency. The most challenging part of the process


was finding the right balance between efficiency and safety, by avoiding procedures that were too complex and that could impede production. For this reason, OMRON worked with the operators themselves to build a shared plan that would uphold the required safety standards but without any detrimental effect on production.


The programme has now spread to all of Campari's other sites worldwide. There is also a handy Campari Handbook, which summarises all of the features of the shared safety model. This means that all of the company's employees are able to operate in line with the same safety standards. This applies not just in terms of compliance with local legislation, but also to a shared way of working in production.


OMRON www.industrial.omron.co.uk/en/home


MAY 2023 | PROCESS & CONTROL 15


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