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Integrated Safety Systems

12/12/2007 7:14 PM

Hi,

How can Integrated Safety Systems be used to improve plant productivity?

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#1

Re: Integrated Safety Systems

12/12/2007 7:22 PM

What are your main issues? If regulatory compliance is one of them then your employees should be protected. Safety awareness is implemented throughout all major industry. Now, if you mean machine safety then we're talking about power and utilities monitoring. Another aspect is safety devices for your people and machines. Product safety is another...,

Where I am going with this is that safety should be implemented throughout...

Safety reassures people that they can have peace of mind while performing their duties. Have an expert do an assessment, Due Diligence is the key.

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#2

Re: Integrated Safety Systems

12/13/2007 7:45 AM

Look into providing your people with proper safety training and responsibility. You only slightly improve productivity through integrated safety systems, but this is hard to prove to the bosses. These are to protect the employees and secondary, your machines.

However!! If your people are well trained and you reduce accidents or injuries, your people will be there to actually do the job. This is where you show your productivity. If an employee is injured and off the job, others must now take up the slack. Loss of production now occurs. Hiring and training someone new is not cost effective to temporarily fill an injured employees position.

Safety systems will help to keep people safe and that is your bottom line. The more you can do to keep them healthy and safe, the better. It's the loss of production from injuries that you can use to prove how well a good safety program can help your company.

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#3
In reply to #2

Re: Integrated Safety Systems

12/13/2007 9:40 AM

I have worked for major companies for the past 25 years. One thing I have learned is that there are no Excuses or Substitute for Safety and Quality. Maybe not 100% but close. I am not a perfectionist but Directives and Regulation and Guidelines are my STAPLE!

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#4
In reply to #3

Re: Integrated Safety Systems

12/13/2007 11:04 AM

Ditto !

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#6
In reply to #4

Re: Integrated Safety Systems

12/13/2007 3:17 PM

Thank You!

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#10
In reply to #3

Re: Integrated Safety Systems

12/14/2007 8:35 AM

Agreed 100%

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#5

Re: Integrated Safety Systems

12/13/2007 11:42 AM

Very easily!

I will give you a real-world example from a project I recently worked on.

A local manufacturer has a process where the palletized finished product moves down an open chainway to a "bagging" station where an operator manually places a plastic bag over the pallet of product before it proceeds through the banding machine. Of course, to accomplish this task, the operator had to stand on and cross the chainway. To correctly comply with OSHA safety regulations, operators were throwing a manual disconnect, applying a padlock to the switch and "trying" the conveyor before proceeding to bag the product. After bagging, the operator would remove their lock and restart the machine. There are two machines side-by-side each putting out one pallet of product every 90 seconds. This was a constant bottleneck for production and two operators had a very difficult time keeping up.

My project designed and installed a safety rated control system that detected the operator's presence near the chainway and automatically shut down the drives when the operator began the bagging operation. Upon completion, the operator only had to push a reset button on the safety system to restart the machine. After installation, one operator can handle bagging both lines and the operation is no longer a process bottleneck. The integrated safety system is properly designed with redundant systems, is safer than the manual method because the operator can't forget to lockout and is far more productive.

This is just one very recent example. The potential is literally limitless, but safety control systems must be well thought out and designed properly. Just throwing some expensive safety gizmos at a machine and hoping for the best will more likely hurt productivity than help. The safety system must be seamless - it must be easier for operators to do the job the safe way than to bypass the system.

If you want more details, let me know. I have designed and installed several integrated safety control systems and would be happy to help you with specific details if you have a project in mind.

Good luck!

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#7
In reply to #5

Re: Integrated Safety Systems

12/13/2007 5:14 PM

Dear CSM Engineer,

Thank you for your response to my question, you were quite helpful.

Anymore details would be greatly appreciated when you have some more time.

Thanks

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#8
In reply to #7

Re: Integrated Safety Systems

12/13/2007 5:30 PM

Let's try to put this in some context...

Do you have a specific project in mind or do you want more on safety control system theory? Feel free to send me a PM if you would rather.

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#9

Re: Integrated Safety Systems

12/14/2007 1:01 AM

What are your improved project?

Your question is too large to answer, but I can say that you can do that if you have enough ideas-time-money.

Good luck.

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#11

Re: Integrated Safety Systems

12/14/2007 9:07 AM

I am fortunate enough to work for a company that puts the highest priority on employee safety and training. In fact, I'm a member of the Corp. Safety Committee and our corporate culture is such that employees are encouraged to report any and all potential safety issues (we're not blowing smoke up their asses...we really mean it and the employees know it). We don't penalize employees for accidentally creating a hazardous situation. We all make mistakes and we try to learn from them and prevent it from happening again.

We are a Fab making nano tech products and MEMS so we use some seriously nasty gases and chemicals including pyrophorics, 14 kW HV supplies for e-guns, and numerous tools running on 480V and 208V 3 phase power.

In spite of the inherent hazards in our workplace we haven't had a serious work related injury in over 7 years of operation. That's a direct result of the seriousness with which we take our safety and training programs. Has this increased our plant productivity? ABSOLUTELY!

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#12

Re: Integrated Safety Systems

12/19/2007 11:44 PM

While discussing on Safety and its benefits, we should inculcate the safety right from Home, imagine if the work person stays unsafe in home, that may affect attendance in work place. Road safety, climatic safety, Safe fooding and so on all affects in work finally. I mean 'safety in totality'. That should be the concept and philosophy while we talk over safety.

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