Turk Banner explains how machine safety indication can greatly increase productivity.
In areas where machine safety systems are employed, operator timing is one of the main culprits for production loss.
Operators often alternate between being too quick to anticipate the safe (muted) part of the machine cycle causing a safety trip, or being too cautious, losing time after the safe part of the machine cycle has begun the next operation.
Safety standards have strict requirements for muting lamps and safety indicators, which cannot be ignored. However, supplemental indication that acts as guidance to the operator and other workers, can have a dramatic effect on increasing productivity.
Of course, if the operator has to change their focus to look for the indicator, or if the indicator is unclear, time and efficiency will be lost. However, the area lighting doesn’t have to be white. By changing the colour of the lighting when it is safe to perform the next task, the operator can observe this with their peripheral vision; no time is lost, and they are unlikely to jump the gun.
The choice of colours is also important. Changing between red and green to indicate unsafe and safe conditions is often a good choice. However, if the operator is required to perform intricate or complex tasks, using a green light may hinder their ability to see clearly, so a more natural white light would be a preferable indication.
If a process has long periods between safe conditions, adding an amber period before the safe time could assist the operator in preparing for the next task. Conversely, for a process with a short cycle time, adding an amber period may hinder the operation by creating a situation where the operator acts prematurely.
In the context of machine safety systems, the psychological effects of lighting are particularly significant. Workers operating heavy machinery or performing intricate tasks require focus and attention to detail. Appropriate lighting helps them see clearly and contributes to a sense of security and confidence in their work environment. When workers feel safe and comfortable, they are better equipped to perform their duties effectively, ultimately driving productivity levels higher.
Safety diagnostics
Another area where production is lost due to safety systems is locating the cause of a safety activation. Sometimes, the cause is obvious if, for example, the operator has been too eager and tripped a safety light curtain. Other activations may be less obvious and much more difficult to diagnose; for example, when a door sags on its hinges and the safety device monitoring it becomes misaligned. In these conditions, choosing a safety system with good diagnostics can save time and stress in resuming production.
Turck Banner offers lighting products and safety systems ideally suited to industrial environments. Its LED lighting and indication range includes products with IP65 and IP69K ratings, which are also resistant to harsh chemicals and cutting fluids. These products can be mounted close to where the light is required, providing bright and uniform illumination that can change colour by hard-wired connection or PLC protocols.
Turck Banner’s safety portfolio also includes illuminated E-Stops, where the whole base turns red if the button is pressed, and safety controllers with in-series diagnostics, which pinpoint the location of the safety device that has been activated and provide device monitoring to give early warning of common problems like misalignment.
The IP65/IP67 safe I/O modules with Profinet/Profisafe and EtherNet/IP/CIP Safety allow Turck Banner to provide a solution for every application scenario: full-safety I/O modules with eight safe inputs/outputs or hybrid I/O modules in which standard and safe inputs/outputs are combined in one device. All modules work independently or in conjunction with external safety PLCs and controllers. The safety configurator allows the device to work as an independent IP67 safety controller, processing safety signals and IO-Link function in a single device.
The compact hybrid controller is unique, as half of the module has safety connections, while the other has non-safety connections. Combining the two halves enables users to analyse in-series safety devices by providing in-series diagnostics via IO-Link. The device lets users control the supplemental indication and lighting via IO-Link or standard I/O ports.
