CHALLENGE:
A food manufacturing client faced increasing safety risks due to employee complacency when accessing safety-critical areas in the packaging section. Workers had begun bypassing safety protocols to address operational issues, leading to a heightened risk of injury. The client needed a comprehensive safety solution that would ensure strict adherence to safety standards without disrupting operations.
Key Achievements
- Comprehensive Risk Assessment: Our team performed an in-depth evaluation of the packaging line, identifying areas prone to unsafe access and operational hazards.
- Advanced Safety System Integration: Designed a safety system that integrates the Allen-Bradley PLC with a SICK controller, utilizing light curtains, door locks, safety switches, and sensors to ensure personnel safety.
- Safety Category 3 (PLd) Compliance: The safety upgrade brought the system up to Safety Category 3 (PLd), ensuring a high standard of safety integrity across the packaging line.
- Seamless Training & Support: Conducted detailed training for stakeholders and provided ongoing support to ensure smooth adoption of the new safety protocols.
SOLUTION:
To address the safety risks, we implemented a robust safety upgrade that integrated the existing PLC with a SICK controller, which manages all safety devices, including SICK light curtains, safety door locks, safety switches, and sensors. This integration ensures that the SICK controller communicates with the Allen-Bradley PLC to automatically de-energize all motion devices when a worker enters a critical area.
The key components of the solution included:
- Light Curtains: These prevent access to hazardous areas by shutting down machinery when the curtain is breached.
- Safety Door Locks and Switches: Installed to ensure that doors cannot be opened without deactivating dangerous machinery.
- Sensors and Switches: Strategically placed to monitor access points and detect unsafe conditions.
Additionally, we supported the system with:
- Concise Training Sessions to familiarize all stakeholders with the new safety features.
- Detailed HMI Screens that clearly display the operational and safety status of all equipment.
- Standby Support to help the client transition smoothly to the new system until they became proficient.
FUTURE OPPORTUNITIES:
This upgrade not only enhances safety but also provides a foundation for future innovations, such as:
- Expanding similar safety measures to other operational areas.
- Incorporating predictive maintenance using data from the safety system.
- Exploring new safety technologies, like remote safety monitoring and AI-powered safety analytics, to further enhance workplace safety.
CONCLUSION:
The safety upgrade has transformed the packaging section into a safer work environment, achieving Safety Category 3 (PLd) compliance. This has significantly improved workplace safety by addressing the risks of complacency and unsafe access. The use of SICK controllers, light curtains, door locks, switches, and sensors ensure a safer working environment, with machinery automatically shut down when workers enter hazardous areas. This solution not only meets the current safety needs but also sets the stage for continuous safety improvements and operational excellence in the future.
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