Safety is always a primary concern when it comes to machinery, but in recent years it has become a greater focus. Not only are precautions and safety systems built into machinery, but separate devices all together are being added with the purpose of replacing traditional, less intelligent safety measures. Traditional measures are able to prevent incidents, but they also hinder production. They are bulky, expensive additions to manufacturing machines that tend to hold production back. New measures can increase efficiency and reduce operation and maintenance costs, all the while improving safety in a plant. Fortunately, these measures are starting to become standardized and more commonplace among a wide array of machines.

Upgrades can start with a control system and safety CPU. The safety controls can then be automated and simplified. Safety PLCs and Remote I/O modules are also being integrated into systems. Safety PLCs can regulate speeds to protect operators’ hands and provide programs that simplify operation calculations. These safety devices can work with the PLCs and I/Os that are already in place, which can streamline functions and improve efficiency. Operators can safely work with different areas of the system while other PLCs are handling things in different zones, which ensure continuous production.

The improved safety machinery is working hand in hand with safety standards to unify safety measures. Using risk assessments (RAs), you can find the best safety solutions for individual systems. RAs can confirm that everything lines up with national and international standards, such as ISO 12100 and ANSI B11.0 for example, to point out faults. From there, you can work with RAs to match up to specific needs within your own production line or plant. Recent adjustments to national standards are lining up more closely with international standards, so new requirements could be very helpful in the long run.