New & Legacy Safety Tech: Strategies to Reduce Risk & Improve ROI

Why This Article is Worth Your Time:

• Learn how to integrate new safety technologies with legacy systems.
• Discover how sensors can reduce human error.
• Explore how GM improved worker safety with simulation technology.
• Gain insights into real-world data on injury reductions, cost savings, and automation adoption rates.

The Growing Role of Software in Safety

Ensuring the safety of industrial equipment, machinery, and personnel requires a comprehensive approach that integrates hardware and software solutions. Traditional safety measures—such as training programs, protective equipment, and compliance with OSHA and IEEE standards—remain essential, but digital transformation has introduced advanced tools that improve workplace safety and efficiency.

Key Safety Technologies

Modern factories rely on sensors, data processing, digital twins, AI, augmented reality (AR), and virtual reality (VR) to prevent accidents before they occur. However, assessing the impact of safety technologies can be challenging due to their preventative nature, making it difficult to quantify direct ROI. To address this, manufacturers should establish a baseline measurement before deploying new technologies and conduct periodic performance reviews.

Safety Software and Data Integration

According to Austin Anderson, Product Owner at Fluke Reliability Azima DLI, safety software is just as crucial as sensor data. A well-integrated system combines sensing technology, data analytics, and control mechanisms to enhance safety monitoring.

Siemens’ Technical Product Manager, Josh Carlson, emphasizes the importance of manufacturing software in planning, simulating, and validating human tasks, robotics, and automation in 3D environments. AI-driven simulation platforms powered by the cloud enable manufacturers to test safety measures before implementation, reducing risks and ensuring compliance with evolving safety standards.

Reducing Human Error with Sensors

While automation improves consistency, human errors can still occur. Dave Cameron, Director of Product Management at Bosch Rexroth, highlights that sensors and cameras when integrated with controllers, help guide operators through correct production processes. For instance, limited-speed safety functions prevent unnecessary downtime while ensuring safety compliance.

T.J. Kusnierek, Sales Product Manager at Bosch Rexroth, adds that manufacturers should not overlook simple yet effective safety solutions like physical protective barriers. These barriers improve safety and integrate easily with existing sensor-based monitoring systems.

Smart Workflows and Human-Centric Safety Solutions

Mark Breese, Principal Consultant at Yokogawa RAP, points out that well-designed software systems help minimize human errors by filtering out irrelevant information, ensuring workers focus on the most critical safety procedures. Reducing cognitive overload enhances worker efficiency and improves mental well-being in high-risk environments.

Overcoming Implementation Challenges

The integration of new safety technologies into legacy systems often presents challenges related to compatibility, training, and costs. Josh Carlson (Siemens) suggests that manufacturers adopt cloud-based solutions, which provide cost-effective, scalable, and secure safety implementations.

Bosch Rexroth’s Kusnierek notes that manufacturers often struggle with the paradox of choice, as the abundance of safety technologies makes it difficult to determine the best solutions. He recommends working with trusted partners to ensure optimal investment in safety systems.

Strategies for Seamless Integration:

• Phased Implementation: Deploy safety systems gradually to minimize disruption.
• Pilot Projects: Test solutions on a small scale before company-wide adoption.
• Continuous Training: Use virtual and augmented reality simulations to enhance workforce adoption.

Case Studies: Automation’s Impact on Workplace Safety

The Manufacturing Sector: Enhanced Safety Through Robotics

Case Study: Toyota’s Production Line Automation
Toyota, a global leader in automotive manufacturing, has extensively implemented robotics in its production lines. One notable example is their use of automated guided vehicles (AGVs) and collaborative robots (cobots) to handle dangerous tasks such as heavy lifting and precision welding.

Impact on Safety:

• Reduced Human Exposure to Hazardous Tasks: Robotics handle high-risk activities, such as welding and material handling, which minimizes the risk of injury for human workers.
• Increased Consistency and Precision: Automation ensures that tasks are performed with high precision, reducing the likelihood of accidents caused by human error.
• Decreased Fatigue: By delegating repetitive and physically demanding tasks to robots, human workers experience less fatigue, enhancing overall workplace safety.

The Healthcare Sector: Minimizing Risks with Automation

Case Study: The Use of Robotic Surgery in Hospitals
Robotic surgery has become increasingly prevalent in hospitals, with systems such as the da Vinci Surgical System enabling minimally invasive procedures. These systems automate complex surgical tasks with high precision.

Impact on Safety:

• Minimized Incisions and Reduced Infection Risk: Robotic systems allow for smaller incisions, which lowers the risk of post-surgical infections and speeds up recovery times.
• Enhanced Precision: Automation provides surgeons with improved control and accuracy, reducing the likelihood of surgical errors.
• Improved Ergonomics for Surgeons: Surgeons operate from a console, reducing physical strain and reducing the risk of repetitive stress injuries.

The Warehouse and Logistics Sector: Automation for Safety and Efficiency

Case Study: Amazon’s Use of Robotics in Warehouses
Amazon’s fulfillment centers have various automation technologies, including robotic picking systems and automated sorting conveyors. These technologies are designed to streamline operations and enhance safety.

Impact on Safety:

• Reduction in Workplace Injuries: Automated systems handle heavy lifting and repetitive tasks, reducing the risk of musculoskeletal injuries among warehouse workers.
• Enhanced Efficiency: Automation minimizes human sorting and inventory management errors, leading to fewer accidents caused by mismanagement or overexertion.
• Real-Time Monitoring: Automated sensors can monitor warehouse conditions and alert staff to potential safety hazards in real-time.

The Construction Sector: Safer Sites with Automation

Case Study: The Use of Drones in Construction
Drones have become integral to construction projects, providing aerial surveillance and data collection. These devices automate site inspections and monitoring.

Impact on Safety:

• Improved Site Inspection: Drones can conduct detailed inspections of construction sites without workers needing to access potentially dangerous areas, reducing the risk of accidents.
• Enhanced Data Accuracy: Automated data collection through drones ensures accurate and timely information, which helps in making informed decisions and avoiding safety issues.
• Reduced Need for Elevated Work: By using drones for aerial views, workers spend less time on scaffolding or other elevated platforms, reducing the risk of falls.

Final Thoughts

The evolving industrial automation landscape presents both opportunities and challenges for manufacturers. While advanced safety technologies enhance workplace security, success depends on strategic implementation, proper training, and ongoing assessments.

Manufacturers can create a safer, more efficient industrial environment by embracing simulation software, sensors, AI, and smart safety solutions while optimizing long-term ROI.