How the Safety Lifecycle Can Improve Productivity

PB 25 Rockwell newlogo 400

June 10, 2022

The term “safety lifecycle” refers to a formalized engineering process that helps create a safety system that can work effectively throughout its lifespan. For example, industrial and manufacturing facilities use safety lifecycles to keep their functional systems operating smoothly.

The safety lifecycle is described in international standards set by the International Electrotechnical Commission (IEC). By standardizing the safety lifecycle, the IEC provides a benchmark for industries and companies that want to meet an acceptable occupational safety level.

Incorporating the safety lifecycle into your operations can increase the effectiveness of your machines while mitigating risks and decreasing operational and engineering costs.

What is the Safety Lifecycle?

The safety lifecycle can be thought of as a series of phases. Each phase is designed to maximize productivity while also improving safety for employees by identifying what steps are necessary for assessing and mitigating risks.

Here’s an outline of a five-step safety lifecycle as defined in IEC 61508 and 62061.

1. Perform a risk assessment

This phase will identify hazards and estimate the risk associated with them. A risk assessment will determine the required Performance Level (PLr) for safety functions. The specific services involved in a risk assessment include:

  •    –   Conformity audits
  •    –   Guarding evaluations
  •    –   Basic safety assessments
  •    –   Term-based risk assessments
  •    –   Development of a corporate safety program

2. Identifying steps to mitigate risks

Based on the risk assessment results, you can determine the functional safety system’s requirements to mitigate any identified risks. This process considers machine interactions and modes of operation. Use industry-acceptable solutions to evaluate the safeguarding options available.

3. Design and verify the system

Once a system is determined, you can choose its architecture. During this step, you will also document the safety circuit design. Finally, the design is verified to meet all requirements, including software and programming.

4. Install and validate the system

After installing the safety system, you will verify that it operates within the defined parameters and complies with standards. This step may involve bringing specialists on-site who can help perform validation testing and document the process.

5. Maintain and make improvements

A safety system must be monitored and evaluated frequently. You will need to verify that the system requirements operate within specified parameters for production, and make system upgrades and improvements as necessary.

After step 5, the cycle repeats itself as you start planning for new functional safety processes to implement.

A Real-World Look at Using the Safety Lifecycle

Here’s an example of how the safety lifecycle can be implemented at an organization.

An industrial company had, over the years, accumulated multiple aging machines. They were older models and had no safety systems in place. These machines were spread out over numerous locations, which made it challenging to systemize or standardize procedures.

So, the company called a vendor to help them improve their safety performance. The company also needed the vendor to train their staff on the new safety systems.

The vendor went through the five-step process of the safety lifecycle to create a consistent mitigation strategy and implement new safety solutions, which they validated. Then, they trained the plant staff on the safety procedures.

By the end of the project, all machines had fully operational, high-performance safety systems in place. These systems were consistent across the company’s multiple locations. Employees at each site were knowledgeable of the new procedures and were fully trained on them.

By taking the time to implement the safety lifecycle into machines that were not standardized and had no safety systems in place, the industrial company improved productivity and mitigated the risks associated with those machines. In addition, by fully training their staff, the company improved the safety of their employees because they understood how to operate and manage the machines across all locations.

Important_Links_Bar.jpg

https://www.rockwellautomation.com/en-us/company/news/blogs/using-safety-lifecycle.html

 

Related Articles

Network Infrastructure Featured Product Spotlight

PBUS 14 Panduit logo 400

This webinar presented by Beth Lessard and Keith Cordero will be highlighting three Panduit solutions that will optimize network equipment and cabling to ensure that your spaces are efficiently and properly managed to support ever-evolving business needs of today and beyond. Products that will be featured include PanZone TrueEdge Wall Mount Enclsoure, Cable Managers, and Adjustable Depth 4-Post Rack.

REGISTER HERE


Editor’s Pick: Featured Product News

Siemens: SIMOVAC Non-Arc-Resistant and SIMOVAC-AR Arc-Resistant Motor Controllers

The Siemens SIMOVAC medium-voltage non-arc-resistant and SIMOVAC-AR arc-resistant controllers have a modular design incorporating up to two 12SVC400 (400 A) controllers, housed in a freestanding sheet steel enclosure. Each controller is UL 347 class E2, equipped with three current-limiting fuses, a non-load-break isolating switch, and a fixed-mounted vacuum contactor (plug-in type optional for 12SVC400). The enclosure is designed for front access, allowing the equipment to be located with the rear of the equipment close to a non-combustible wall.

Read More


Sponsored Content
Electrify Your Enterprise

Power is vital to production, and well-designed control cabinets are key. Allied Electronics & Automation offers a comprehensive collection of control cabinet solutions including PLCs, HMIs, contactors, miniature circuit breakers, terminal block connectors, DIN-rail power supplies, pushbutton switches, motor starters, overloads, power relays, industrial Ethernet switches and AC drives engineered to keep your operations running safely, reliably and efficiently.

Learn more HERE.


Products for Panel Builders

  • OKW: IK/IP-Rated SOLID-BOX for Industrial Touch Screen and Display Electronics

    OKW: IK/IP-Rated SOLID-BOX for Industrial Touch Screen and Display Electronics

    More electronics designers are specifying OKW’s tough SOLID-BOX to safeguard sensitive touch screens, control panels and displays in harsh industrial environments. IK 08 (impact) and IP 66/IP 67 (ingress) protection make SOLID-BOX ideal for plant and machine construction, HVAC, IoT/IIoT, Smart Factory/Industry 4.0, gateways, data loggers, ICT, electrical installations, measurement/control, agriculture/farming, sensor systems and safety… Read More…

  • LOVATO Electric: New Double Contact Elements and Auto-Monitoring Contact Element

    LOVATO Electric: New Double Contact Elements and Auto-Monitoring Contact Element

    LOVATO Electric enriches the range of pushbutton and selectors Platinum series with the new double contact elements and auto-monitoring contact element. The double contact elements provide the flexibility of two contacts (1NO+1NC, 2NO or 2NC) within the same dimensions as a single contact (LPXC10 or LPXC01). The new auto–monitoring contact is replacing the previous auto-monitoring contact versions (LPXC01SM and LPXC02SM)… Read More…