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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Safety System Development Process
& Con...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Session Purpose and Intent
 This session is meant to outl...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 3
Agenda
Closing & Wrap-up
Sample Project Utilizing the to...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety System Development Process
4
 Common Safety System...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Most People Use the Common Approach!
5
 Most people only ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Proper Approach: A standards Based
Methodology!
6
 Bo...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Development Considerations!
• What machine/machines are to...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 8
Agenda
Closing & Wrap-up
Sample Project Utilizing the to...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Rockwell Automation Approach
Follows the “Safety Life ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation follows the safety life cycle to
evalu...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reser...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
What is an
assessment
and how do I
do it?
Step 1: The Asse...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation Utilizes 3 types
of Assessments!
Safet...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reser...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Main Reason for Developing
a Functional Spec!
The SRS ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reser...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
My assessment &
requirements spec
sure made this
easy!
The...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2007 Rockwell Automation, Inc. All rights reser...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © Rockwell Automation, Inc. All rights reserved.
...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Product Selection Options!
 The risk assessment tool iden...
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Select Devices to Make Complete Solutions!
Safety
Controll...
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Safety Relay/Safety Controller/
Safety PLC Selection Matri...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety Output Selection!
Safety Contactors & Relays
• Simp...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Scalable Safety Solutions
Integration Continuum
Offering s...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
How do I verify
my design!
The Design Phase Also Includes ...
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Design Verification Methods –
Option 1 - Calculation Metho...
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a
b
c
d
e
PerformanceLevel
Designated
Architecture
Desig...
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Design Verification Methods –
Option 2 - SISTEMA Method
28...
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Design Verification Methods –
Option 3 – SAB & SISTEMA Met...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reser...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
How do I install my
safety system?
Step 4 - Installation
•...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
How do I validate
my safety system?
• Validation considera...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reser...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
How do I operate
my machine?
Step 5 – Operate, Maintain & ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
How do I maintain
my safety system?
Step 5 – Operate, Main...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reser...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 37
Agenda
Closing & Wrap-up
Sample Project Utilizing the T...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation moved into the number 1 provider of
sa...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation’s Investment in Technologies!
• Integr...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation’s Investment in Services!
 Assessment...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation’s Investment in Tools!
Safety Return-O...
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Safety System Development Tools
42
SAB
Safety Automation B...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
What is Safety Automation Builder (SAB)?
SAB is a new tool...
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SAB helps tie the two sides of Functional Safety together
...
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Qty Catalog Number Description DS List Ea Typical Delivery...
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ProSafe Builder - Trapped Key Configuration
Software
 The...
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Safety System Investment Justification Tool
47
Safety Retu...
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Justification Of Safety Investments
48
 So, how do I just...
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What is the Safety ROI Calculator Tool?
49
The industries ...
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ROI Example Output!
50
The Safety ROI tools helps customer...
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Safety System Design Tools
51
Safety
Functions
Safety Func...
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52
Safety
Life Cycle
5. Maintain
and Improve
1. Hazard or ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Safety Functions are the Building Blocks of
Machinery Safe...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The More Complicated the Machine
the More Safety Functions...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
• Safety Functions include GSR relay solutions and GuardLo...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 56
Sample Safety Function
Safety Function: Emergency Stop
...
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IA Safety Accelerator Toolkit
Development Tools and Quick ...
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IA Safety Accelerator Toolkit
Safety Application Examples
...
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Instruction Faceplates
59
 Want to troubleshoot safety in...
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Safety Accelerator Toolkit
Guard I/O Status and Diagnostic...
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Safety Performance Tools for GuardLogix
 TUV Recognized A...
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GuardLogix Safety Estimator
 Safety Tool to help estimate...
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Connected Component Building Blocks for Safety
63
Pre-desi...
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Implementation & Documentation
64
 Okay Here’s What We Ac...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 65
Agenda
Closing & Wrap-up
Sample Project Utilizing the T...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
The Safety Process – What do I do?
66
 Ok, I need to make...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Let’s Look at a Sample Machine!
67
 We are going to use t...
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Machine Description
68
Infeed Conveyor
Outfeed
Conveyor
Ro...
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Step 1 – Risk Assessment
69
 We are going to develop a ri...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Step 1: Details
70
 Normal operation
 Maintenance
 Set-...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 71
Show how the ISO12100 risk methodology is
used to deter...
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Step 2: Write a Functional Specification
72
 The assessme...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Define Our Safety Functions
 When Door Opens in zone #1, ...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 74
Show how to develop a functional specification.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Step 3: Develop a safety project utilizing
Safety Automati...
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Users can now start the safety selection process by select...
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Users can view the selected safety devices for each access...
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Users can verify their design by exporting the SAB file to...
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Completed Bill of Material from
ProposalWorks & SAB!
79
Th...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 80
Show how to develop an SAB project.
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Now we Have a Price! We Need to Justify
the Investment!
81...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 82
Show how to develop a justification
report using the RO...
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The Next Step After Selection, Design
Verification & Justi...
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Let’s search for the applicable safety functions!
84
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
An Additional Tool that Can Help is the
Safety Accelerator...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Let’s search for the applicable safety accelerators!
86
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
An additional tool that can help is Connected
Component Bu...
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Let’s search for the applicable safety
building blocks!
88
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Summary
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
Rockwell Automation - the Global Leader
in Safety (Service...
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
We care what you think!
 On the mobile app:
1. Locate ses...
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PUBLIC INFORMATION
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Safety System Development Process and Configuration Tools Overview

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In this session, you’ll learn how to dramatically reduce development and deployment time of safety systems using the Safety Life Cycle methodology and an array of tools available from Rockwell Automation. You’ll use a range of tools to help you determine return on investment for safety projects, design safety functions and systems, select appropriate safety devices, and ensure that your system meets global safety standards and directives being
increasingly specified by manufacturers.

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Transcript of "Safety System Development Process and Configuration Tools Overview"

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Safety System Development Process & Configuration Tools Overview Chris Brogli – Global Business Development Manager, Safety
  2. 2. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Session Purpose and Intent  This session is meant to outline the steps of developing machinery safety solutions and tools that can help reduce the time to develop, implement and start up a machinery safety system.  Additional sessions (SF02, SF03, SF04 & SF05) break this process down in more detail.
  3. 3. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 3 Agenda Closing & Wrap-up Sample Project Utilizing the tools Selection, Design, Verification, Development & Justification Tools Safety Life Cycle Utilization Safety System Development Process
  4. 4. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety System Development Process 4  Common Safety System Development Process  Machine review & hazard identification  Product Selection  Safety System Design  Safety System Installation  Start Production  Proper Safety System Development Process  Risk Assessment  Functional Specification Development  Product Selection  Structure Selection  Design  Design Verification  Installation  Verification & Validation  Training  Operation & Maintenance
  5. 5. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Most People Use the Common Approach! 5  Most people only analyze automatic operations!  Fact – 60 to 70% of all injuries occur outside of normal production activities.  Most people identify hazards and immediately select safety devices/solution without considering the effects on productivity!  The number 1 cause of safety system failures is because the solution is bypassed. This happens because it was not designed to accommodate job tasks.  Most safety systems that follow the common process result in significant reductions in equipment utilization! Most people have never been to a training session or have never read a machinery safety standard! This results in safety systems that are inadequate, ineffective & improperly designed.
  6. 6. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Proper Approach: A standards Based Methodology! 6  Both EN, ISO and ANSI standards require a systematic approach for safety system development!  So which standard is right for you? S1 S2 E1 E2 R1 A1 A2 A1 A2 A1 A2 A1 E1 E2 R2A R2B R2B R2C R3A R3B R4 S1 S2 F2 F1 a b P1 P2 e c d P1 P2 P1 P2 P1 P2 F2 F1 b c d OR ANSI/RIA Method EN/ISO Method Either is OK but the move is towards the ISO method because of new tools!
  7. 7. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Development Considerations! • What machine/machines are to be guarded? • What are the characteristics and limits of the machine/machines? • What are the different modes of operation of the machine/machines? • Who interacts with these machines during normal and abnormal operation? • What are those people doing? • How does the machine need to function in each mode of operation? • Are these any special system needs? • What type of diagnostics is needed? • What type of system performance is needed? • What is the target efficiency rate of the machine/machines? • What is the company specification? • What can be done to improve safety and productivity? What do I need to consider?
  8. 8. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 8 Agenda Closing & Wrap-up Sample Project Utilizing the tools Selection, Design, Verification, Development & Justification Tools Safety Life Cycle Utilization Safety System Development Process
  9. 9. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Rockwell Automation Approach Follows the “Safety Life Cycle” 9 1. Assessment The Machinery Safety Life cycle is a defined process that is followed to ensure that proper safety practices have been implemented! 5. Operate, Maintain & Improve 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification
  10. 10. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation follows the safety life cycle to evaluate machinery safety solutions because: • It removes uncertainty and eliminates omissions and errors! • It provide a repeatable process that leads to complete safety solutions. An idea without a plan leads to indecision, omissions and mistakes! Rockwell Automation Safety Life Cycle
  11. 11. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 11 Step 1 in the Machinery Safety Life Cycle is the Assessment! 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification Proper safety system development starts here!
  12. 12. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What is an assessment and how do I do it? Step 1: The Assessment. The Foundation of Safety System Development! Machine Characteristics/Limits Risk Evaluation Hazard Identification Risk Estimation Risk Reduction Risk Tolerable OK Too High Risk Assessment Process according to ISO12100
  13. 13. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation Utilizes 3 types of Assessments! Safety Service Hazard / Guarding Assessment Safety Assessment / Audit Team-Based Risk Assessment Identifies Primary Hazards Assessment & Estimate Detailed Risk Assessment Purpose Identifies guarding/ hazards for immediate plant actions Most common – provides report & estimates to develop safety plans In-depth analysis required for critical or special machines Service Deliverables • One Page Report identifying hazards and “Risk-in” rating only • Does not include: o Risk Out rating o Cost estimation o Pictures • Assessment led by RA Consultant, limited customer involvement • Report per standard  Identification of primary hazards/tasks  List non-compliance issues  Risk In / Risk Out Rating  Mitigation Guarding and Controls recommendations  Prioritized recommendations for safety improvements  Photograph of critical identified hazards (based on customer approval)  Cost estimate per machine • Team-based assessment led by RA Consultant for all machine life phases • Report per standards  Identification of primary hazards/tasks  List non-compliance issues  Risk In / Risk Out Rating  Mitigation Guarding and Controls recommendations  Prioritized recommendations for safety improvements  Photograph of critical identified hazards (based on customer approval)  Cost estimate per machine • Mitigation Drawing • Includes ergonomics review (slip, trip, and fall hazards) XX Scalable assessment solutions to meet any need!
  14. 14. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 14 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification Step 2 in the Machinery Safety Lifecycle is the Safety Requirements Specification! The SRS defines the functional requirements of the safety system!
  15. 15. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Main Reason for Developing a Functional Spec! The SRS defines my solution! • It identifies how the machine is to operate in each mode of operation for each person that interacts with the machine! • It identified special needs like: (Safe-speed/Safe-direction/Zone control/Etc.) • It also identifies any special diagnostics and interface needs!
  16. 16. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 16 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification Step 3 is the Selection, Design & Design Verification Phase. This step focuses on safety system design, product selection, circuit selection and design verification!
  17. 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. My assessment & requirements spec sure made this easy! The Design Phase Includes Selection of Mitigation Techniques, Products, Circuit Designs & System Structure Determination! Design considerations: • What mitigation technique should I use? • What circuit structure should I use? • What safety products should I use? • What type of control system should I use? (Relays/Controllers/PLC’s) • What type of special operations do I need? (Zone control/Safe-speed/etc.) • Where are all of my safety devices? • What kind of interactions are needed for auxiliary machines? • What kind of diagnostics do I need? • Should I use hardwiring or networked systems?
  18. 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2007 Rockwell Automation, Inc. All rights reserved. 18 Possible Mitigation Techniques! Design it out Fixed enclosing guard Monitoring Access / Interlocked Gates Awareness Means, Training and Procedures (Administrative) Personal protective equipment Most Effective Least Effective Hierarchy of Protective Measures
  19. 19. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © Rockwell Automation, Inc. All rights reserved. Types of Categories (Structures) CAT B/1 CAT 2 CAT 3 CAT 4 (higher diagnostic coverage that CAT 3)
  20. 20. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Product Selection Options!  The risk assessment tool identified the required performance level and Category that is required for each part/portion of the machine. Use products that meet the required performance level (PLr) and/or the Category level as directed by the risk assessment. Note: A safety system is made up of the following components:  Safety input devices/actuators  Safety control/logic devices  Safety output devices Remember your weakest link sets your maximum system performance that can be achieved!
  21. 21. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Select Devices to Make Complete Solutions! Safety Controllers Relays Systems Safety PLCs VFD’s Contactors Servo’s Input Logic Output
  22. 22. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Relay/Safety Controller/ Safety PLC Selection Matrix! Safety Relays • 1 Zone • Local/Hardwired I/O • Simple Safety Logic • 1 to 2 dual channel Inputs • 2 to 3 outputs Safety Controllers & Expandable Relays • 1 to 3 Zones • Local & Distributed I/O • Simple & Complex Safety Logic • 1 to 20 dual channel Inputs • 1 to 20 outputs • Basic Diagnostics thru PLC Safety PLCs • More Than 3 Zones • Distributed I/O • Simple & Complex Safety & Standard Logic • 1 to 100 dual channel Inputs • 1 to 100 outputs • Advanced HMI Diagnostics
  23. 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Output Selection! Safety Contactors & Relays • Simple on/off control • Power control • Signal control Safety Variable Frequency Drives • On/off control with the ability to control & monitor speed Safety Servo Systems • On/off control • Speed control • Direction control • Position control • Location control • Acceleration control • Decceleration control
  24. 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Scalable Safety Solutions Integration Continuum Offering solutions that fit your needs, not ours! Cost-effective Component Solutions Mid-Range Solutions Integrated Solutions Low High Simple connectivity Mechanical linked machine Stand alone machine Low cost Just enough control Multi-axis motion Increased controller capabilities Mix of mechanical and electrical controls Low engineering costs Coordinated multi-axis motion Robotic feeders Electronic line shafting Advanced connectivity Advanced information capabilities Components & Intelligent Motor Control Integrated Architecture 2424Copyright © 2011 Rockwell Automation, Inc. All rights reserved.
  25. 25. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. How do I verify my design! The Design Phase Also Includes Design Verification! Design verification considerations: • What do I need to do to verify my design? • What is meant by system structure? • What product information do I need? • Where do I get product safety data? • What verification tool should I use?
  26. 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Design Verification Methods – Option 1 - Calculation Method 26 MTTFd Mean Time to Dangerous Failure Low 0 -10 Years Medium 10-30 Years High 30-100 Years DC Diagnostic Coverage = Detected Dangerous Failures / All Dangerous Failures None DC < 60% Low 60 < DC < 90% Medium 90 < DC < 99% High DC >99%
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.27 a b c d e PerformanceLevel Designated Architecture Designated Architecture Designated Architecture Designated Architecture Designated Architecture Designated Architecture Designated Architecture Cat B Cat 1 Cat 2 Cat 2 Cat 3 Cat3 Cat 4 DC avg DC avg DC avg DC avg DC avg DC avg DC avg <60% <60% 60% to < 90% 90% to < 99% 60% to < 90% 90% to < 99% 99% Structure (Category) Diagnostic Coverage (DC) Reliability (MTTF) Confirming PLr is Achieved by… Balancing Structure (Cat), Reliability (MTTFd) and Diagnostic Coverage (DCavg)
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Design Verification Methods – Option 2 - SISTEMA Method 28 SISTEMA is a free design verification tool that is internationally recognized!
  29. 29. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Design Verification Methods – Option 3 – SAB & SISTEMA Method 29 SAB utilizes SISTEMA for design verification but simplifies the process by using menus and questions!
  30. 30. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 30 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification Step 4 Ensures that the System was Installed Properly and that the System Functions as Intended! This step focuses on ensuring that the safety system was installed properly and that there is a defined process for validating system performance!
  31. 31. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. How do I install my safety system? Step 4 - Installation • Installation considerations: • There should be specific instructions regarding physical barrier installation! • There should be specific instructions regarding safety product installation and wiring! • There should be specific instructions regarding wiring methods and grounding! • There should be specific instructions regarding panel fabrication and wiring! • There should be specific instructions regarding signage installation and location! • There should be specific layout drawings showing a routing, mounting and installation instructions! • There should be specific electrical schematics regarding terminations & connections.
  32. 32. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. How do I validate my safety system? • Validation considerations: • There should be specific instructions regarding the validation of for each safety function! • This means that each safety input, logic & output device must be tested to ensure it functions as intended! • This means that each combined function of input/logic/output must be tested to ensure that it functions as intended! • This means that each programmed function is validated to ensure it functions as intended! • There should also be specific instructions regarding fault injection to test the safety ! • Common testing methods include: • Shorting wires, breaking connections, removing wires, etc. Step 4 Continued - Validation
  33. 33. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 33 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification Step 5: Operate, maintain and improve ensures that the system is operated properly and that the system is maintained to ensure continued effectiveness! Step 5 focuses on ensuring that the safety system is operated properly and maintained to ensure continued effectiveness!
  34. 34. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. How do I operate my machine? Step 5 – Operate, Maintain & Improve • The should be training for all personnel that will be interacting with the machine. • The training should include: • Intended use • Safety system components training • Normal operations • Safety system operations
  35. 35. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. How do I maintain my safety system? Step 5 – Operate, Maintain & Improve • The standards say that periodic testing should be done to verify proper system functionality. (There is no defined period or timeline that is suggested) • The standards also require additional assessments after machine modifications. This might include: • Program changes • Safety system use • Hardware changes • Machinery changes • System modifications
  36. 36. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.Copyright © 2011 Rockwell Automation, Inc. All rights reserved. 36 5. Operate, Maintain & Improve 1. Assessment 4. Installation & Validation 2. Functional Requirements 3. Selection, Design & Verification The Machinery Safety Life Cycle Never Ends! The cycle never ends. The system must be re-evaluated anytime modifications occur and each step must be followed!
  37. 37. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 37 Agenda Closing & Wrap-up Sample Project Utilizing the Tools Selection, Design, Verification, Development & Justification Tools Safety Life Cycle Utilization Safety System Development Process
  38. 38. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation moved into the number 1 provider of safety solutions because of investment in products, services & tools that help customers maximize performance!
  39. 39. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation’s Investment in Technologies! • Integrated Safety Platforms • Safety Instructions & Applications • Functional Safety Compliance • Embedded Safety Capabilities • Advanced Safe Motion Functions • Integrating Control, Safety & Motion • CIP Safety for DeviceNet & EtherNet/IP • Low Cost Safety Networks • Dual Port EtherNet/IP The broadest portfolio of safety products in the industry!
  40. 40. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation’s Investment in Services!  Assessments  Arc Flash Analysis  Hazard  Risk  LOTO  HAZOP  Validation  Safety circuit analysis  Machine stop time services  Conformance audits  Safety system validation  Compliance Consulting  CE conformance  Functional safety (ex. ISO 13849-1 and IEC 62061, ISO, ANSI, IEC, CE, OSHA, NFPA, CSA, AS ) 200+ Safety Professionals Available Globally 100+ Machinery Safety Certified Resources 80+ Process Safety Resources Over 200 Training Courses for help customers develop competency 30 + RA Safety Professionals 3 RA Safety Partners – 20 Resources 4 Safety Professionals 20+ RA Safety Professionals 12 RA Safety Partners – 24+ Resources 20+ Safety Professionals 6 Safety Professionals 5 Safety Professionals 5 Safety Professionals  Training  TUV Certification  Risk Assessments  Safety Standards  Safety Products  Arc Flash  LOTO  Integration / Start Up  Circuit/logic design  Installation  Arc flash remediation  MCC Arc Flash upgrades  Project Management  Remediation Solutions  Complete Turnkey Systems The most complete suite of safety services in the industry!
  41. 41. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation’s Investment in Tools! Safety Return-On-Investment Tool Find out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return- On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications. Safety Functions Safety Functions Program The Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan. SAB Safety Automation Builder The Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation. Safety Accelerator Toolkit Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates. Connected Components BB Connected Components Building Blocks These building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the ProSafe Builder ProSafe Builder The ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map. The broadest suite of safety tools in the industry!
  42. 42. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety System Development Tools 42 SAB Safety Automation Builder The Safety Automation Builder software package that allows users to import images of their machines. Users can identify hazardous access points and the associated hazards in order to develop a list of safety products that will be used to mitigate the risk. This gives the customer a complete drawing, a bill of material and SISTEMA calculation. ProSafe Builder ProSafe Builder The ProSafe Builder software gives users the ability to layout complete trapped key solutions for machinery safety applications with a tool that generate a bill of material and system configuration schematic/map.
  43. 43. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What is Safety Automation Builder (SAB)? SAB is a new tool designed to help develop complete safety system solutions. These solutions include conceptual layout drawings that includes zones, physical guards, hazards, access points and the products used to protect personnel.
  44. 44. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. SAB helps tie the two sides of Functional Safety together by providing a method to select the safety products that are required to complete a safety solution! Risk Assessment Design Verification Determines (PLr) Confirms PLr Achieved
  45. 45. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Qty Catalog Number Description DS List Ea Typical Delivery 1 445L-P4E0600FP Micro 400 Safety Light Curtain, Pair, Res 30mm, Pt Ht 600mm E8 $ 1,220.00 Preferred 2 445L-AC8RJ5 M12 to RJ45, 5 meter E8 $ 26.30 Preferred 1 440R-ACABL2 Ribbon cable 10 pin for 2 extenstion E8 $ 36.46 1 440R-P226AGS-NNR MSR42 Multi function Controller for GuardShield Light Curtains E8 $ 507.00 Preferred 1 440R-D22R2 Guardmaster Safety Relay, 2 Dual Channel Universal Inputs, 1 N.C. Solid State Auxiliary Outputs E8 $ 402.99 Preferred 1 100S-C37EJ14BC MCS 100S-C Safety Contactor, 37A, 24V DC (w/Elec. Coil), Bifuracated Contact B7 $ 411.07 1 1754-L28BBB GuardPLC 1200 - Packaged Safety Controller, 28 I/O D5 $ 6,120.60 1 1753-DNSI GuardPLC DeviceNet Safety Scanner D5 $ 1,141.30 2 1753-IB16 Digital Input Module, 16 Inputs, 24V DC D5 $ 1,787.70 Preferred SAB – The Complete Safety System Design & Verification Tool that Leaves Customer with a Complete Bill Of Material! Complete Safety System Layout Performance Level Verification Complete Bill of Material
  46. 46. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. ProSafe Builder - Trapped Key Configuration Software  The software will allow users to layout trapped key systems in a systematic method that shows a flow view of configured and selected products. The comprehensive trapped/captive key tool on the market!
  47. 47. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety System Investment Justification Tool 47 Safety Return-On-Investment Tool Find out how to quantify the savings and productivity gains from safety investments. The Rockwell Automation Safety Return- On-Investment Tool accounts for improved safety, reduced claims, improved productivity, and other issues unique to safety applications.
  48. 48. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Justification Of Safety Investments 48  So, how do I justify a safety investments on my machine? A. Based on the costs of an incident that could be avoided B. You don’t; Just do the minimum to comply with a standard C. Based on the potential for productivity improvement D. Based on the fine from a non-compliance finding E. Perform an ROI Answer: “E” Good News! Rockwell Automation Can Help With A Safety ROI Calculator “But how do I calculate a Safety ROI?”
  49. 49. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What is the Safety ROI Calculator Tool? 49 The industries only return on investment tool for safety projects!
  50. 50. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. ROI Example Output! 50 The Safety ROI tools helps customers justify safety projects based on project cost and injury avoidance calculations!
  51. 51. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety System Design Tools 51 Safety Functions Safety Functions Program The Safety Functions Program is building block approach to designing safety systems. Each building block has a complete documentation package that includes a description of each safety function, an electrical schematic, a bill of material, a SISTEMA verification calculation and a verification and validation plan. Safety Accelerator Toolkit Safety Accelerator Toolkit This toolkit provides easy to use system design, programming, and diagnostic tools to assist you in the rapid development and deployment of your safety systems using GuardLogix, Compact GuardLogix, or SmartGuard 600 Controllers, Guard I/O, and Safety Devices. The toolkit includes a risk assessment and system design guide, hardware selection guide, CAD drawings, safety logic routines, and operator status and diagnostic faceplates. Connected Components BB Connected Components Building Blocks These building blocks are tools that help customers develop safety solutions that utilize component class safety solutions. These building blocks include sample programs, electrical schematics and configuration document that help in the
  52. 52. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 52 Safety Life Cycle 5. Maintain and Improve 1. Hazard or Risk Assessment 4. Installation and Validation 2. Functional Safety System Requirements 3. Design and Verification Identify Hazards & estimate the associated risk System Architecture Safety critical circuit design Guarding design Validation protocol Based on: - Risk Assessment - system performance - applicable s standards Final site assembly Commissioning/Validation Training Final Risk Assessment Validation Verify that system requirements operate within specified parameter for Production and Safety Preventative maintenance and system upgrades Safety Functions Help Customers Move Beyond the Risk Assessment with Complete Rockwell Solutions!
  53. 53. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Functions are the Building Blocks of Machinery Safety Solutions! Risk Assessment Model & Confirm PLr Determines (PLr) Confirms PLr Achieved To Realization and PL evaluation
  54. 54. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The More Complicated the Machine the More Safety Functions You Need! E-Stop Device 1 E-Stop Device 2 Light Curtain 1 Door Interlock 1 Logic Output 1 Output 2 Output 3 SF1 SF2 Logic SF3 SF4 Output 4Logic Logic Large and complex machines may require multiple safety functions to provide a complete machine safety solution. Safety function documents are 1 way that Rockwell Automation can help!
  55. 55. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. • Safety Functions include GSR relay solutions and GuardLogix solutions. • The initial 6 Safety Functions launched October 1st. • Two additional ones launched in February. • 13 additional Safety Functions will be added by the end of 2014! • Each safety function includes a functional specification, a electrical diagram, a program or configuration document, a SISTEMA verification report and a verification & validation document to help users develop safety solutions quickly, easily and accurately with minimal effort. Introducing the Safety Functions Library
  56. 56. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 56 Sample Safety Function Safety Function: Emergency Stop Products: Light Curtain / GuardLogix Safety Rating: PLe, Cat. 4 to EN ISO 13849.1 2008 . Introduction Important User Information General Safety Information Safety Function Realization Setup and Wiring Configuration Programming Falling Edge Reset Calculation of PFHd Verification and Validation Plan Additional Resources
  57. 57. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. IA Safety Accelerator Toolkit Development Tools and Quick Start Guide Simplified Wiring Preconfigured Logic Quick Start Manual Preconfigured HMI
  58. 58. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. IA Safety Accelerator Toolkit Safety Application Examples 58 Example Code I/O Configuration Diagnostics
  59. 59. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Instruction Faceplates 59  Want to troubleshoot safety instructions from your HMI?  NOW YOU CAN  Display the instruction as the Function it is performing.  Estop  Light Curtain  Light Curtain Muting  Etc. 59
  60. 60. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Accelerator Toolkit Guard I/O Status and Diagnostic Faceplates
  61. 61. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Safety Performance Tools for GuardLogix  TUV Recognized Analysis Tools  Single Channel Safety Reaction Time Tool  Network Reaction Time Tool
  62. 62. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. GuardLogix Safety Estimator  Safety Tool to help estimate system performance and network configuration.
  63. 63. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Connected Component Building Blocks for Safety 63 Pre-designed Building Blocks with source code, drawings and quick-start guide to help you develop safety solutions!
  64. 64. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Implementation & Documentation 64  Okay Here’s What We Accomplished So Far…  Identified the Hazards and Documented Our Risk Assessment  Developed the functional specification to Mitigate the Risks  Designed the Safety Solution & Selected Components  Verified the design to confirm the achievement of the required system performance.  Performed an ROI analysis demonstrating the value of the safety system  Leveraged example code, faceplates, wiring diagrams etc.     Complete documentation for your safety solution!  
  65. 65. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 65 Agenda Closing & Wrap-up Sample Project Utilizing the Tools Selection, Design, Verification, Development & Justification Tools Safety Life Cycle Utilization Safety System Development Process
  66. 66. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Safety Process – What do I do? 66  Ok, I need to make my machine safe. Now what?  Four Questions To Navigate the Jungle  What do I need to do?  What are my options?  How much do they cost?  Which option is right for me? Let’s Look at a Couple of Options…
  67. 67. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Let’s Look at a Sample Machine! 67  We are going to use the safety tools to develop a safety solution utilizing Safety Automation Builder. This will leave us with a concept drawing, a design verification and a complete bill of material.  We will use the ROI tool to help the customer justify the project.  We will then search for solutions for the selected products using safety functions, safety accelerator toolkit and connected components building blocks.
  68. 68. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Machine Description 68 Infeed Conveyor Outfeed Conveyor Rotary Table Label P&P Label Feeder Hot Glue Gun Product
  69. 69. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Step 1 – Risk Assessment 69  We are going to develop a risk assessment utilizing the ISO12100 evaluation method. S1 S2 F2 F1 a b P1 P2 e c d P1 P2 P1 P2 P1 P2 F2 F1 b c d
  70. 70. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Step 1: Details 70  Normal operation  Maintenance  Set-up  Adjustment  Change-over  Start-up  Decommissioning  Etc. Identify the hazards and associated risks! Develop a functional specification that outlines how each hazard needs to be protected for each mode of operation. Thermal Hazard Crushing Hazard Pinching Hazard Pinching Hazard It is estimated that 60 to 70% of all injuries happen outside of normal production activities yet most people spend 90% of their efforts around designing for production activities!
  71. 71. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 71 Show how the ISO12100 risk methodology is used to determine the required system performance that is to be implemented.
  72. 72. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Step 2: Write a Functional Specification 72  The assessment defined the task and associated hazards and the required system performance that is required.  The function specification will determine the required safety functions, their design requirements and the type of functionality that is needed for each mode of operation for each person that interacts with the machine.
  73. 73. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Define Our Safety Functions  When Door Opens in zone #1, tray packing stops, zone #2, tray forming continues.  Safety Function:  Safety related stop function initiated by a safe guard  Stopping hazardous movement  Triggering Event:  Opening of guard door Zone #1 Zone #2 Follow this Process for Every Safety Function in Every Machine Mode!
  74. 74. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 74 Show how to develop a functional specification.
  75. 75. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Step 3: Develop a safety project utilizing Safety Automation Builder 75 This screen shot shows the layout drawing with identified hazard locations and access points that need to be protected!
  76. 76. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Users can now start the safety selection process by selecting input, logic and output devices for each identified safety need! 76 This screen shot shows the layout drawings with the selected safety devices!
  77. 77. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Users can view the selected safety devices for each access point by clicking on the table view! 77 This screen shot shows the devices that were selected for each safety function!
  78. 78. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Users can verify their design by exporting the SAB file to SISTEMA for design verification! This is a sample report. 78 This screen shot shows the safety design verification report from SISTEMA!
  79. 79. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Completed Bill of Material from ProposalWorks & SAB! 79 This screen shot shows the completed bill of material for the labeler machine safety system!
  80. 80. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 80 Show how to develop an SAB project.
  81. 81. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Now we Have a Price! We Need to Justify the Investment! 81  We will use the Safety Return on Investment Tool to justify the project based on projected reductions of injuries and productivity enhancements! Let’s calculate our savings and ROI for this machine example!
  82. 82. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 82 Show how to develop a justification report using the ROI calculator!
  83. 83. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Next Step After Selection, Design Verification & Justification is Design! 83 Now we need to start making schematics, developing programs and configuration documents. We will guide you to locations that can help! The Safety Functions documents are found on the safety resource center!
  84. 84. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Let’s search for the applicable safety functions! 84
  85. 85. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. An Additional Tool that Can Help is the Safety Accelerator Toolkit 85 Safety Accelerator Toolkit The Safety Accelerator Toolkit can be found on the safety resource center or by asking your local Rockwell distributor!
  86. 86. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Let’s search for the applicable safety accelerators! 86
  87. 87. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. An additional tool that can help is Connected Component Building Blocks for Safety 87 The Safety Building Blocks can be found by asking your local Rockwell distributor for a CD!
  88. 88. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Let’s search for the applicable safety building blocks! 88
  89. 89. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Summary
  90. 90. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation - the Global Leader in Safety (Services/Products/Solutions)! Best in class assessment services to help you to determine safety system needs! Safety Design Tools and resources to help engineers and designers with safety system development. Products selection and design verification tools to helps engineers select product quickly and accurately. Installation and start-up services to help meet productivity and start-up needs. Validation services to ensure that the safety system operates as designed and constructed. Preventive maintenance development services to ensure the safety system continues to operate properly.
  91. 91. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. We care what you think!  On the mobile app: 1. Locate session using Schedule or Agenda Builder 2. Click on the thumbs up icon on the lower right corner of the session detail 3. Complete survey 4. Click the Submit Form button 91 Please take a couple minutes to complete a quick session survey to tell us how we’re doing. 2 3 4 1 Thank you!!
  92. 92. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Questions?
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