Safety Risk Assessment Case Studies | Safety Engineering, Part 3

Safety Risk Assessment Case Studies

De-Risked Solutions for Manufacturing Automation

As we discussed in Safety Part 2, through a Safety Risk Analysis (SRA), our engineers are able to help you de-risk equipment hazards. We generate a comprehensive analysis and detailed record of all safety hazards associated with the setup, operation, and maintenance of your automated equipment.

From the insights gleaned from the SRA, we can recommend design improvements and safer processes that directly impact the outcome of your automated equipment and overall project success.

Any automation project can benefit from some level of de-risking. To learn more about the importance of de-risking engineering projects, see Safety Part 1 | Risk Analysis Approaches for New or Existing Equipment.

Here are just a few AC safety risk assessment case studies and how a focus on de-risking equipment and tasks can ensure operator safety and translate to overall design success.

SRA Case Study #1 | De-Risking Manual Handling Processes for a Precision Robotic Part Handling & Inspection Cell

Engineering Challenge

AC Manufacturing Automation was engaged to design of an automated precision part handling and inspection cell and solve related manual handling processes:

1. Manual removal of specialized material coupons by hand
2. Manual inspection of with a microscope to identify quality issues with tearing or poor edges
3. Manual quality assurance of passed outcomes and placement into a tray for further processing

SRA Case Study of an automated precision part handling and inspection cell

Challenges Created by Manual Handling

> Ergonomic and time constraints while using hand tools to complete careful removal of a product from its base material
> Frequent damage to high value material product resulting from manual removal
> Time-consuming and highly subjective manual inspection process

SRA Impacts to Design

AC Manufacturing Automation recommended a SRA to thoroughly identify the tasks and functions of the manual processes. Risks were identified, evaluated, and mitigation measures implemented.

The positive results of the initial SRA led to further de-risking of the project beginning at the concept completion phase through end of IAT, resulting in risk reduction of all impacted operations:

> Installation – Identified and mitigated install risks
> Initial Startup – Identified and mitigated initial startup risks, with emphasis on robot motion and teaching hazards
> Routine Operation and Production – Identified and mitigated risks involved with the day-to-day use of the machine
> Fault Recovery – Identified and mitigated risks when recovering from faults
> Routine Maintenance – Identified and mitigated risks when performing maintenance activities

Manufacturing Automation Success

By leveraging the insights and risk reduction measures of targeted SRAs, AC Manufacturing Automation developed a successfully de-risked automated robotic work cell.

The work cell delivered improved processing and performance for all challenges and complexities, with a dramatic reduction in processing time, including:

> Robot removal of product using vacuum EOAT
> Robot places the product on a vision system for detailed and objective inspection (go/no-go)
> Robot places the product on output tray

SRAs provided further guidance at the end of project to identify subsequent improvements with future replications in the automation roadmap.

SRA Case Study #2 | De-Risking Electrical Component for a Safety Retrofit of Existing Equipment

Engineering Challenge

AC Manufacturing Automation was engaged in this safety risk assessment case study to enable a mechanical update of a component installed on existing equipment, which identified the following challenges:

> Electrical actuator on existing equipment operated on high voltage
> Electrical actuator was insufficient for application (binding, poor movement, etc.)

SRA Case Study on a High Voltage Actuator

SRA Impacts to Design

AC Manufacturing Automation recommended a SRA to thoroughly identify the tasks and functions connected with the high voltage actuator. Risks were identified, evaluated, and mitigation measures implemented.

The positive results of the initial SRA led to further de-risking of the project beginning at the concept completion phase through end of IAT, confirming the need for a safety retrofit to address all impacted operations:

> Operator Safety – Identified level of risk to operators and machinery associated with the actuation system
> Routine Operation and Production – Identified risked associated with operator activities and points of interaction with machinery
> Troubleshooting – Identified risked associated with technician troubleshooting activities involved with fixing machinery and resolving downtime
> Routine maintenance – Identified risked associated with maintenance and repair of machinery
> Non-routine maintenance – Identified risked associated with major repairs (replacement of pump, motor, cylinders, etc.)
> Ancillary activity (non-operator activity) – Identified previously unknown and improper use of the machinery room as storage area for de-risking

Manufacturing Automation Success

By leveraging the insights and risk reduction measures of targeted SRAs, AC Manufacturing Automation successfully completed a safety retrofit to upgrade the existing mechanical actuator with a pneumatic actuator to ensure safety and performance requirements, while de-risking operational hazards for overall improved safety.

SRA Case Study #3 | De-Risk Operations for a Multi-Cell Production and Conveyance System

Engineering Challenge

In this safety risk assessment case study AC Manufacturing Automation was engaged to engineer to de-risk a manufacturing line of multiple cells to enable automated production of medical devices, which involved the following challenges:

> Manual production could not deliver required precision for medical devices
> Manual production could not deliver required high-volume output for medical devices
> Client did not have labor resources to meet requirements

SRA Case Study on Multi-Cell Production and Conveyance System

SRA Impacts to Design

AC Manufacturing Automation recommended multiple extensive SRAs (and FMEA for machinery safety – See Part 4) to thoroughly identify the tasks and functions of each robot cell in the automation line to de-risk operator interaction in all stages of setup, production, and maintenance:

> Installation – Identified and mitigated install risks
> Initial Startup – Identified and mitigated initial startup risks (especially robot motion and teaching)
> Routine Operation and Production – Identified and mitigated risks with the day to day usage of the machine in various categories
> Fault Recovery – Identified and mitigated risks in the fault recovery process
> Routine and Non-Routine Maintenance – Identified and mitigated risks related to maintenance activities

Risks were identified, evaluated, and mitigation measures implemented.

Manufacturing Automation Success

By leveraging the insights and risk reduction measures of targeted SRAs, AC Manufacturing Automation recommended and designed a fully de-risked automated production line for medical device manufacturing.

De-risking delivered key safety and production requirements, including:

> Operator risks were redefined and limited to parts replenishment
> Production quality and efficiency was achieved by automating all stages across multiple robot cells
> Medical device manufacturing precision and production requirements were met

Partner with AC to Integrate SRAs into Successful Manufacturing Operations

Whether through an SRA or FMEA approach, AC can help you identify risk reduction measures that make a significant impact on the safety and performance of your new and existing manufacturing automation equipment.

By embracing risk using proven processes, you prevent deploying equipment that might lead to injuries or failures during operation and ensure a more efficient and cost effective implementation.

> Do you need to de-risk a new manufacturing automation challenge?
> Are you concerned with safety or performance risks with existing manufacturing automation equipment?
> Did you inherit legacy equipment that may have unidentified safety or performance risks?
> Could your team benefit from a conversation with risk management engineers who can listen to your challenges and help uncover hidden risks?

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