How can you design a machine that is safe for users and operators?

Create a team with fresh eyes - they will see more than the person who setup/designed/installed the application or process in the first place.

Identifying hazards and assessing risks are foundational steps in designing safe machinery. Hazards encompass potential sources of harm like moving parts or chemicals, while risks evaluate the likelihood and severity of harm. Utilizing tools such as HAZOP, FMEA, or risk matrices aids in systematically identifying and analyzing hazards and risks. By comprehensively understanding potential dangers, designers can implement effective safety measures, ensuring the protection of users, operators, and the environment. This proactive approach fosters a culture of safety and compliance, minimizing the potential for accidents or harm throughout the machine's lifecycle.

We are following below ISO, ANSI & IEC standards for machine safety. ISO 12100:2010 - General principles for design - Risk assessment and risk reduction ISO 13849-1 - Safety-related parts of control systems - Part 1: General principles for design ISO 14119 - Interlocking devices associated with guards - Principles for design and selection ISO 10218-1 - Safety requirements for industrial robots - Part 1: Robots ISO 13850 - Emergency stop - Principles for design ANSI B11 series - American National Standards for machine safety IEC 60204-1 - Safety of machinery - Electrical equipment of machines

In the design of safe machinery, applying relevant design principles and standards is paramount. Principles like simplicity, redundancy, and fail-safe design enhance safety and reliability, while ergonomic considerations optimize usability. Adhering to design standards such as ISO, ANSI, OSHA, or CE ensures compliance with legal and ethical obligations. By integrating these principles and standards into the design process, engineers mitigate hazards and risks effectively, safeguarding users, operators, and the environment. This approach fosters a culture of safety, aligning with regulatory requirements and industry best practices.

Machine Design with Safety: Design machines with interlocks for safety, physical guards, emergency stops, and sensors to detect hazards. Implement interlocks to prevent operation when guards are open. Use safety PLCs for monitoring. Here are some examples which I have used earlier. Example 1: Incorporate light curtains in a press machine to detect entry into hazardous zones, stopping operation instantly. Example 2: A robotic assembly line equipped with emergency stops, light curtains, and sensors to ensure operator safety during operation. Example 3: Install pressure sensors in a hydraulic press, stopping it if abnormal pressure is detected.

Implementing effective safety measures and controls is essential in designing safe machinery. Utilizing the hierarchy of controls enables prioritization of measures like elimination, substitution, engineering controls, administrative controls, and personal protective equipment (PPE). These measures aim to prevent or mitigate harm from hazards and risks, safeguarding users, operators, and the environment. By systematically addressing safety concerns, designers create a comprehensive safety framework that minimizes potential hazards. This proactive approach not only enhances worker protection but also aligns with regulatory requirements and industry best practices.

Learn about your local legislations/rules! Having designed items for EU/UK/US it’s incredible difficult to find a “one size fits all” approach. Another one - ISO Standards don’t always cover everything.