How can you ensure the safety of machine tool systems in a collaborative environment?

The very first step should be hazard identification, through involvement of all stakeholders. As also required during HIRA. Communication of all hazards and mitigation measure is very critical. Some of the tools from TPM e.g. safety map, PPE matrix are very useful as these make use of more visuals than just text as incase of most risk assessment tools. Training needs must also be identified and appropriate trainings must be ensured. These should include e.g. LOTOTO including control on stored energy etc. Supervisory controls and refreshing knowledge through tool box talks, behavior based safety observation are also very helpful. As cultural change never happens overnight.

Ensuring the safety of machine tools in a collaborative environment involves implementing various measures: Risk Assessment: Conduct a thorough risk assessment to identify potential hazards Safety Standards: Adhere to and implement relevant safety standards Protective Barriers: Install physical barriers or safety fences to prevent human contact with the machine during operation. Sensors and Vision Systems: Utilize sensors, cameras, and vision systems to monitor the surroundings in real-time. Force and Contact Sensors: Emergency Stop Systems: Collaborative Robot Programming: Training: Maintenance and Inspections: Documentation: Collaboration with Experts:

For use of any tool or machinery under collaborative environment it is essential that a control of work system must be utilised. Use of such tools and machinery must be authorised by a person in charge. An example is the use of tools in a shipyard, wherein every tool has an identification number, issued under PTW at a tools store and deposited back at the end of work. Similarly, machinery must be used under a combination of controlled systems such as PTW, LOTO, work registers, RFID tagging, realtime tracking software and alert systems. Awareness and training are also important for such equipment. Not to mention a robust maintenance system that includes OEM requirements for periodic maintenance and condition monitoring.

Lockout Tagout (LOTO) is a safety procedure that protects people and machine in a collaborative environment. Some manufacturing companies stated integrating their employee ID scanning for additional safety. We can use Collaborative Robots (Cobots) that are specifically designed for safe interaction with humans and machine tools in a collaborative environment. Use collision detection sensors, force and torque sensing. We need to provide training to all workers on safety procedures, emergency protocols, and proper interaction with machine tool systems. This training should cover hazard recognition, risk mitigation techniques, and the use of personal protective equipment (PPE)

There should be practise of Pre Start up review for machines also to align further review of EOM guidelines, Record keeping in place.Priotise machine guarding, Emergency stop,Nomenclature, operator Competency,also considering present practise vs IMS, Responsible care, Sustainability driven code of practice etc..

Exactly, training is crucial for individuals to understand and adhere to safety standards. - It ensures that employees are familiar with the established protocols, guidelines, and industry best practices. - Through training, individuals gain the knowledge and skills necessary to comply with standards, promoting a safer work environment. This not only reduces the risk of accidents but also helps in maintaining regulatory compliance and upholding the overall safety culture within an organization.

Thorough training and the right people for the task is key. The notion that anyone can do anyone’s job is completely wrong. Each and every one of us has a talent or special skill sets that are different from others. For example: the analogy of a basketball team. Yes, everyone can throw a ball in the basket, but can they play/shoot like Michael Jordan or Kobe Bryant? Players/workers can be trained, but they will never perform like the one that has the specialized skills/talents from many years of experience. Experience/talents cannot be replaced. That is why there are different salary level for the same position. To summarize it all up: Training for the most-fit employee for the task is key to safety for all machine systems and equipment.

A NR 12 é a Norma Regulamentadora e seus anexos definem referências técnicas, princípios fundamentais e medidas de prote??o para resguardar a saúde e a integridade física dos trabalhadores e estabelece requisitos mínimos para a preven??o de acidentes e doen?as do trabalho nas fases de projeto e de utiliza??o de máquinas e equipamentos, e ainda à sua fabrica??o, importa??o, comercializa??o, exposi??o e cess?o a qualquer título, em todas as atividades econ?micas, sem prejuízo da observancia do disposto nas demais NRs aprovadas pela Portaria MTb n.o 3.214, de 8 de junho de 1978, nas normas técnicas oficiais ou nas normas internacionais aplicáveis e, na ausência ou omiss?o destas, opcionalmente, nas normas Europeias tipo “C” harmonizadas.

Different standards and regulations govern machine tool systems based on the equipment's type, function, and location. These rules cover design, installation, operation, maintenance, inspection, and worker training and certification. It's crucial to know and strictly adhere to these standards, such as ISO 12100, ANSI B11, and OSHA 1910.

A mi me ah resultado util utilizar las normas de seguridad que rige la organización al momento de realizar un movimiento o una instalación de un equipo para así tomar una la mejor decisión.

Machine tool systems often feature safeguards like guards, shields, barriers, sensors, interlocks, emergency stops, and warning signs to protect from dangers like moving parts, sharp edges, heat, sparks, and noise. These safeguards should always be used correctly and never altered without approval. Regular inspections should be conducted to identify and report any damages or defects.

As zonas de perigo das máquinas e equipamentos devem possuir sistemas de seguran?a, caracterizados por prote??es fixas, prote??es móveis e dispositivos de seguran?a interligados, que resguardem prote??o à saúde e à integridade física dos trabalhadores. Quando utilizadas prote??es que restringem o acesso do corpo ou parte dele, devem ser observadas as distancias mínimas conforme normas técnicas oficiais ou normas internacionais aplicáveis. A instala??o de sistemas de seguran?a deve ser realizada por profissional legalmente habilitado ou profissional qualificado ou capacitado, quando autorizados pela empresa.

After the equipment is installed, it is necessary to invite a third party to conduct an inspection to make sure that each fuse meets the manufacturer's recommendations. If any changes are to be made by a third party or by any experienced specialist to further develop the safety protection system, the manufacturer should be consulted. Then, using the manufacturer's use manual, an instruction manual for the employees will be prepared.

Direct causes of majority incidents are unsafe acts. Unsafe acts are mainly contributed because of less than adequate awareness. Communication helps improve awareness. Orientation, trainings, propaganda posters One point lessons, pictogram at point operation etc are the methodologies can be adopted for creating awareness on hazards.

The leaders must consistently drive an environment and expectation of safety first. When I installed my first safety system on equipment in a factory, I trained with all shifts and the shift leaders and plant manager were there to start each training with me. They kicked it off by saying they want productivity but MUST have safety first. And they led that expectation long after I was done installing the equipment.

Training and Awareness Past Incidents Detailed Incident Investigation Employee Motivation Programme and Brain Storming

Communication, collaboration and coordination with your coworker in a collaborative environment is of utmost importance. Each move must be carefully coordinated so that all parties involved in the collaboration are aware of what the steps are, and what will be exactly happening each time by doing this, it leaves no room for error, or at least very little room.

System does not allow people to use their creativity in handling situations of unpredictable hazards. When you allow collaboration, individuals can use synergy and creativity to think and communicate to predict, assess and avert hazards. Most of the management personnel forget this aspect and give importance to machine safety and not people safety. Allow the operator/s to own the machine, machine will be safe.

Machine tool systems demand routine upkeep for their safety and performance. Following manufacturer instructions and company protocol for system maintenance like cleaning, lubricating, adjusting, and repair is necessary. Maintenance activities should be logged and issues reported. It's also beneficial to seek ways to boost safety by implementing new technologies or practices that improve system efficiency, reliability, or usability.

I agree. By implementing a SOP (Standard Operating Procedure) for the machine tools which included daily to yearly checklists kept at the machine on what should be done to ensure successful operation and longevity of the machines. This included specific step-by-step procedures with illustrations from pre-operation to end of operation. It also had lists of fluids and consumables with part numbers to ensure consistency. Not only was this a guideline, but acted as training material for new employees.

A NR 12 prevê manuten??o de máquinas e equipamentos contemplará, quando indicado pelo fabricante, dentre outros itens, a realiza??o de Ensaios N?o Destrutivos - ENDs, nas estruturas e componentes submetidos a solicita??es de for?a e cuja ruptura ou desgaste possa ocasionar acidentes. Os ENDs, quando realizados, devem atender às normas técnicas oficiais ou normas técnicas internacionais aplicáveis. Nas manuten??es das máquinas e equipamentos, sempre que detectado qualquer defeito em pe?a ou componente que comprometa a seguran?a, deve ser providenciada sua repara??o ou substitui??o imediata por outra pe?a ou componente original ou equivalente, de modo a garantir as mesmas características e condi??es seguras de uso.

Machine tool systems are setup to provide us the highest amount of precise manufacturing / machining possible to develop the product / process. They are a complex assembly of various mechanisms along with electronics and controls. Thus, in a robust , daily operation cycle, these systems need proper care and attention to run them longer. In my opinion, Preventive Maintenance is the most important routine which needs to be used. Checking the mechanical components for lubrication, damage, timely replacement, calibration, even cleaning is quite necessary to keep these complex systems running. Failure to follow a PM may result in damage of even a small component, which may lead to catastrophic failure

En mi opinión este punto es el que respalda a todos los anteriores, si bien puede haber normas que regulen los lineamientos de seguridad, sistemas que ayuden a mantener un área de trabajo segura y tecnologías que ayuden a hacer los equipos más eficientes, el mantenimiento autónomo es el pilar para el sostenimiento y la vida prolongada de las máquinas y herramientas.

Given the evolving nature of machine tool systems and associated standards, continual learning is critical. Attending relevant training sessions, workshops, or webinars and reading materials such as manuals, journals, and blogs can keep you updated. Sharing experiences and learning from colleagues' feedback and suggestions can also enrich your knowledge.

Continuous improvement in all processes and procedures. This recurring process of optimization is the path to excellence in prevention mechanisms.

Logically, this safety is known to most of the people who have had a lot of experience in the manual part of the machine tool and for this reason are familiar with the various tools of machining processes. Otherwise, the theoretical and written knowledge of this subject will be very difficult to understand. As a result, the most important item is the manager's experience related to this department, he must have enough experience in the machine tool sector to be able to master the diameter and size of different tools and materials in the project (this is the most important principle of safety in the machine tool sector) The issue of safety in the machine tool sector will be very wide due to industrial complexities.

Visual display is one of the key areas to focus that will give knowledge and reference to check and act for all operators. Visual displays help us to learn, review and focus on our failures.

Fauiler of safety systems in machine tools because of the inappropriate design, specially during the operating time, some time safety systems makes inconvenience to machine operators and they used to bypass or modify as per their convenience,so we need to incorporate the operators convenience along with the mistake proof design.

Um exemplo que considero útil é incluir nas auditorias escalonadas os itens de prote??o individual e também os itens de prote??o coletiva, mas nada disto funciona se a equipe n?o está bem treinada para realizar tais auditorias

La visualización es un elemento clave en cualquier proceso. Hacer partícipe al operador de los elementos visuales del entorno aseguran un mayor compromiso con la seguridad. Del mismo modo que reflejar los días sin incidentes junto a una instalación fija un compromiso individual con el cero accidentes.