Real World Example - Prototype System in the Automotive Industry

A manufacturer in the automotive industry was developing a prototype system for a production line that included robots and operator work stations.  Questions arose concerning how to determine the most appropriate risk reduction methods between area scanners, light curtains or fixed guarding.  costs of each of these solutions vary, as does the feasibility of their effective use.  To determine which solution provided the best risk reduction at a reasonable cost, the company used the risk assessment process.

 

In the course of performing the risk assessment, the manufacturer also identified previously unknown hazards that had been designed into the system.  For example, the system included overhead proximity sensors.  The task-based risk assessment identified that these switches would need to be adjusted or replaced from time to time.  At that point the team realized that there was no safe way that a maintenance person could work at height to perform that task.  No tie-off anchor points were designed into the system, and the location precluded the use of man lifts.  To perform this task would require the maintenance person to break the company rule of working at heights without fall protection.  The changes to the prototype system included installing appropriate anchor points to the design.

 

Through the risk assessment process, this manufacturer was able to optimize spending on risk reduction devices, and also to identify previously unknown hazards.