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New standard will formalize an OEM's approach to machine safety

The recent approval of B155.1 could bring a profound change to the way packaging machinery is designed and built, say these three machine safety experts.

Approved April 25, 2006, ANSI/PMMI B155.1 is a new safety standard for packaging machinery and packaging-related converting machinery. The standard describes procedures for identifying hazards, assessing risks, and reducing risks to an acceptable level over the life cycle of a piece of packaging machinery.

Chairing the ANSI/PMMI 155.1 Committee was Fred Hayes, director of technical services at the Packaging Machinery Manufacturers Institute (PMMI). Hayes agreed to join Packaging World in an August 3 conference call to tease out the implications of the new standard for both builders and buyers of packaging machinery. Also on the call were two additional members of the ANSI/PMMI B155.1 Committee: Bruce Main, president of safety consultancy Design Safety Engineering Inc., and Jeff Bloomer of Sara Lee Food and Beverage. Presented here is a portion of the August 3 conference call.

PW: Why a new safety standard? Hasn't safety always been at the top of the list where packaging machinery is concerned?

Hayes: You're right, it has. Look at any packaging show and it's plainly evident. Safeguards, interlocks, light curtains, and other safety devices are everywhere. But this standard changes things because it places so much emphasis on risk assessment. A lot of times in the past, people might look at a machine and say, “I have this type of hazard and so I'm going to put an interlock guard in place and that will prevent people from getting into the machine and injuring themselves.” But risk assessment brings a more structured element to it all. You pinpoint the hazard and ask how it can be mitigated. You get further into visualizing what people do, what tasks are they trying to perform, and how they interface with the machine.

PW: So it isn't that builders of packaging machinery haven't had safety on their agenda, it's just that they haven't been as rigorous in their approach to achieving safety through risk assessment?

Hayes: Their approach to risk assessment hasn't been as formalized as the new standard suggests they be. The new standard calls for a risk-scoring method. It requires the machine builder to pick some type of safeguarding device and then assess the probability and severity a second time to document that the risk has been reduced. It's this element of documentation that's really new.

Main: The primary requirement out of the standard is that risks have to be reduced to an acceptable level, and that's in Clause 5 of the document. As long as the manufacturer or user can do that and can demonstrate that they've reduced risk to an acceptable level, that's great. That is what the requirement is. The standard actually has a higher expectation now of being able to demonstrate what you've done. So what's new is the depth of the analysis that is now possible. The task-based approach that Fred talked about is really digging at a little deeper level than what we've been able to do in the past.

PW: I've heard it said that B155.1, whose chief objective is to bring about new levels of safety, should also bring greater levels of productivity and efficiency and even cost savings. That seems too good to be true. Why will it work that way?

Main: Because it will bring about a better understanding of what people are doing with machines at a deeper level. And once you understand that, the ways to make the machines better just kind of jump out at you.

Hayes: A lot of it depends on the approach you take to risk assessment. If you do the risk assessment two days before you ship the machine, you're going to have an assessment for the machine done, but you are not going to get any of the benefits of doing the assessment in terms of trying to find productivity gains and these other things. So really at that point, you've kind of added costs. On the other hand, if you do the assessment early in the design process, early enough to figure out what this machine is going to do and how it needs to meet the customer's requirements, then you can bring change to the design more cost effectively because you're dealing with ideas, CAD drawings, and things like that, as opposed to going out and cutting metal on the floor. So it's how and when you implement risk assessment that determines whether or not you get the gains in terms of cost reduction and productivity.

PW: Moving it forward from the earliest stages is the key?

Hayes: Correct.

Main: To a certain extent, OEMs will be verifying what they already know, which is that they make good machinery. We're not expecting them to go through this process and suddenly discover they've got all kinds of problems. So a lot of the work that they're going to be doing is really documenting and verifying that what they've done reduces risk to an acceptable level.

Bloomer: I would also think that this is a sort of a discovery process, so that what comes to light are newer technologies or other ways of mitigating a risk. I think the risk assessment is going to help people walk through that mental exercise of really identifying not the least-cost method of mitigating risk but the best method of mitigating risk.

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