25 novembre 2010 safe maintenance through design from machine engineering for safe maintenance to...

25 Novembre 2010

Safe Maintenance through design

From machine engineering for safe maintenance tomaintenance engineering for safe machine

Workshop Maintenance – Bruxelles – Novembre 2010

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mailto:[email protected]

Contents

From machine engineering…> Regular and normative framework: main requirements and recommendations> Main issues (accidents analysis)> Is « good » design enough?

… to maintenance engineering> More than a « simple intervention »: a complete process

Conclusion > Designer/ User Dialogue > Training

Workshop Maintenance - Bruxelles25/11/2010 2

Maintenance & Design

A regular framework: machinery directive 2006/42/EC

1.1.2. Principles of safety integration: Machinery must be designed and constructed so that it is fitted for its function, and can be operated, adjusted and maintained without putting persons at risk when these operations are carried out

1.6. MAINTENANCE – > Adjustment and maintenance points must be located outside danger zones. It must be

possible to carry out adjustment, maintenance, repair, cleaning and servicing operations while machinery is at a standstill

> If it cannot be satisfied for technical reasons, measures must be taken to ensure that these operations can be carried out safely (see section 1.2.5)

> Machinery must be fitted with means to isolate it from all energy sources.> Machinery must be so designed, constructed and equipped that the need for operator

intervention is limited.> 1.6.5. Cleaning of internal parts

1.7. INFORMATION - 1.7.4. Instructions


Machine engineering

A regular framework: machinery directive 2006/42/EC

1.7.4.2. Contents of the instructions - Each instruction manual must contain:> (e) the drawings, diagrams, descriptions and explanations necessary for the

use, maintenance and repair of the machinery and for checking its correct functioning;

> (q) the operating method to be followed in the event of accident or breakdown> (r) the description of the adjustment and maintenance operations that should

be carried out by the user and the preventive maintenance measures that should be observed;

> (s) instructions designed to enable adjustment and maintenance to be carried out safely, including the protective measures that should be taken during these operations;


Machine engineering

Normative framework

No specific safety of machinery standard relative to maintenance (maintainability)

EN ISO 14122: Permanent means of access to machinery

EN 547-1: Human body measurements

French standard: NF X 60-301 : Guide for taking into account criteria for maintenability of durables for industrial and professionnal use

EN 1037 – safety of machinery Prevention of unexpected start-up

Reference standard on safety on machinery: EN ISO 12100> Same recommendations than directive requirements


Machine engineering

Normative framework: EN ISO 12100

3.3 maintainability (of a machine)> ability of a machine to be maintained in a state which enables it to fulfill its function under

conditions of intended use, or restored into such a state, the necessary actions (maintenance) being carried out according to specified practices and using specified means

4.11.9: Control mode for setting, teaching, process changeover, fault-finding, cleaning or maintenance

4.11.12 Provision of diagnostic systems to aid fault-finding> Diagnostic systems to aid fault finding should be included in the control system so that there

is no need to disable any protective measure. NOTE Such systems not only improve availability and maintainability of machinery; they also reduce the exposure of maintenance staff to hazards.

4.15 Limiting exposure to hazards through location of the setting and maintenance points outside of danger zones


Machine engineering

What kind of occupational accidents ?

Analysis of 93 accidents of « repair » - Main « direct » risk-factors> Intervention when machine powered on: 76 % of accidents

• machine fully operated : 40 %• machine automatically started up : 25 % • machine intentionally switched on : 25 %

> Statutory safety devices missing: 41 % of accidents> Release of energy: 14 %> Deactivation of safety devices: 11%


Machine engineering

8

OA Distribution/ EPICEA working phase

Workshop Maintenance - Bruxelles25/11/2010

0

5

10

15

20

25

30

30

22

14

98

5 53 3

2

%

Working PhaseReparing

Cleaning

Diagnosis

Testing

Jamming (Malfunction)

Lubrication

Inspection

Re-commissionning

Setting

Undetermined

EPICEA study

9

OA Distribution/ risks factors


0

5

10

15

20

25

30

35 31

21

14 1412 12

9 9 8 7 74

21

%

Risks factors Isolation/lock-out missing

Maintenability

Inadequate knowledge

Accessibility

Machine fully operates

Isolation/lock-out error

safety deactivation

Coactivity

Devices missing

Undetermined

Intentionnaly start up

Automatically start up

Isolated Work

Equipment availability

EPICEA study

10

Conclusion of OA analysis


Machine engineering

Intervention under energy

Maintainability has to be improved

Safety measures must be adapted to the intervention

Integration at design stage to be prioritized

It’s essential to identify intervention needs


Maintenance : high-risk activity?

Ensure safety on energies

Organizethe activity




Train operators



??Analyze,

Estimate,

Prevent

Risks

Maintenance : In reality !

Not just a « simple intervention » but a complete process

Not only consider the intervention on machinery

Before intervening

After intervening

Each maintenance stage contributes to safe operation performance on work equipment


Maintenance Engineering

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25/10/2007

Maintenance generic Chart

Process External entity informationSub-process

Humanresources

Control stocks

Management

Produce

Exploit results

Prepare/schedule

Identify intervention prioritiesPrepare resources and

schedule actions

Assess need Issue intervention request

TriggerPolicy

Policy

Machine

Schedule

Machine

Equipment

Equipment

Personnel

Methods

REXdatabase

Intervention request approved

Diagnostic report

Actions to be performed

Actions performed

Observe symptoms and identify causes

Diagnose

Intervene on equipmentIsolate Equipment De-isolate Equipment

Conduct tests Perform work Return to service

Gather InformationDraft report Store information

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Thinking aimed at designers

A machine must be designed such that it can be safely maintained without necessarily resorting to a maintenance operation under isolated conditions

To optimize conditions under which a maintenance operation is performed

> eliminate or limit it whenever possible through appropriate equipment design choices

> integrate maintainability

> analyze operating modes in relation to this maintenance operation based on zones, durations and

the work to be performed

> analyze and assess risks for each operating mode,

> derive safety measures appropriate to this operating mode,

> knowing that each technical solution has its limits, derive compensatory measures, if necessary,

it is important to consider the consistency of adopted safety measures, depending on the type of operation: a solution retained for a maintenance operation can be incompatible with another operation.


Conclusion

Designer/ User dialogue


Conclusion

Concerning designers: difficulties to forsee some « specific » modes: process observation

Concerning users: difficulties to anticipate some intervention: breakdown, spare parts…

Information have to be shared : dialogue - specification formalisation Operators training

> Before putting machine into service> During the life of the machine (changes)> drawings and diagrams available and up to date !.

19Workshop Maintenance - Bruxelles25/11/2010

Safe maintenance is making progress

25 novembre 2010 safe maintenance through design from machine engineering for safe maintenance to...

Documents

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maintenance adjustment

safe maintenance

maintenance points

maintenance design slide

activity workshop maintenance

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