Automated production: Integrated protection

According to the HSE, almost 700,000 workplace injuries occur every year in the UK. This is estimated to cost employers a total of £3.17 billion. Unsurprisingly the manufacturing industry suffers from one of the highest accident rates, meaning that it bears the brunt of these costs. To avoid workplace injuries and costly insurance pay-outs, employers need to be aware of the latest technologies available to make the workplace safe.

Regulations

There are many environments in the workplace where certain areas need protection. For example many production cells may involve operations which are potentially hazardous to personnel or machinery that is nearby and therefore need to be sheltered. The Health & Safety at Work Act (HASWA) requires all employers to protect the health and safety of everyone in the workplace, including those just visiting the premises such as delivery drivers and visitors who may not be familiar with the site, so it is important that such sheltering works at all times.

Integrated automation

Automated production lines bring huge benefits to manufacturers as they can operate continuously with no risk of human error. Automated cells which may cause welding splatter or flying sparks etc. are often positioned behind machine protection doors which improve the efficiency of a work space by reducing the area that needs to be kept clear due to potential hazard. As with all safety equipment, it's important to ensure that doors specified for a machine protection application incorporate all the required features. Access to a machine may need to be repeated regularly and in some cases the machine may need to be isolated prior to entry so proper integration with the production systems is crucial.

Due to the vital work that these safety doors perform in maintaining a site's efficiency and the safety of personnel, many industrial door manufacturers now offer products which are bespoke designed for the job. For example sara LBS has developed the Rapid Protect series of high speed roller shutter doors which have been designed in consultation with manufacturing clients. The high speed doors can be fully integrated within the production facility to ensure both machinery and personnel are properly protected.

Reliability

With access systems such as this, reliability is a key consideration as any performance issues directly affect production efficiency. The combination of speed and repeated opening needs to be carefully controlled to ensure safe and smooth operation. This can only be achieved by designing a system based on expert knowledge and working closely with the client to ensure the required system is delivered.

A major part of the design is the materials used to produce the finished product as they must simultaneously provide protection from hazards and enhance reliability despite frequent use. The use of transparent sections of curtain to allow visibility of machinery may be required, or in the case of welding equipment, the use of flame retardant material or the provision of anti-UV windows; all aspects of operation must be considered in order to deliver not only the customer's requirements but those of HASWA.

Innovation and performance

sara LBS's range of machinery protection doors includes doors suitable for most locations and environments; including the Rapid Protect 2000, a high speed aluminium door for machinery and laser protection, or the Rapid Protect 300 which comes as standard with a noise-reducing RollTex curtain, with optional alternatives including transparent PVC with coloured safety stripes.

The Rapid Protect range has been designed to cause minimal interference with the production process while still delivering absolute protection. The door can be integrated into the automated assembly process and features a failsafe Category 4 PLe - ISO 13849-1 switch which detects when the door is fully closed and prevents machine start-up until then. This enables a rapid switch from complete isolation of a production stage to easy access in a matter of seconds.

The fast operation is made possible with sara LBS's MCC Vector Control System that delivers smooth acceleration and operation and reduces wear. This allows the Rapid Protect doors to reach operating speeds of up to 2.4m/s and gives operators the chance to programme separate opening heights for different components passing through.

Automated production is a fantastic tool for improving a site's efficiency. However, due to the inherent lack of supervision in these areas it is essential that safety is treated as a priority. Most good suppliers will be able to specify and install a bespoke system of machine protection doors which are tailored to your specific needs; as well as provide after sales servicing and maintenance support.