ANSI B11-20 - Safety Requirements For Integrated Manufacturing Systems

ANSI B11.
202004
American National Standard for Machine Tools
Safety Requirements for

Integrated Manufacturing Systems
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AMERICAN NATIONAL STANDARDS

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ii
TABLE of CONTENTS
PAGE
FOREWORD...............................................................................................................................................V
EXPLANATION OF THE FORMAT, AND ANSI B11 CONVENTIONS...................................................VII
INTRODUCTION......................................................................................................................................VIII
1
SCOPE ................................................................................................................................................ 1
1.1
1.2
GENERAL ...................................................................................................................................... 1
EXCLUSIONS ................................................................................................................................. 1
NORMATIVE REFERENCES.............................................................................................................. 2
DEFINITIONS ...................................................................................................................................... 3
RESPONSIBILITY ............................................................................................................................... 7
4.1
4.2
4.3
HAZARD CONTROL......................................................................................................................... 11
5.1
5.2
TASK AND HAZARD IDENTIFICATION .......................................................................................... 11

RISK ASSESSMENT / RISK REDUCTION ...................................................................................... 12
DESIGN AND CONSTRUCTION ...................................................................................................... 13

6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12
6.13
6.14
6.15
6.16
6.17
6.18
6.19
6.20
6.21
6.22
6.23
SUPPLIER'S RESPONSIBILITY ....................................................................................................... 7

USER'S RESPONSIBILITY .............................................................................................................. 8
PERSONNEL RESPONSIBILITY .................................................................................................... 10
GENERAL .................................................................................................................................... 13
LAYOUT DESIGN REQUIREMENTS ............................................................................................. 13
ELECTRICAL EQUIPMENT REQUIREMENTS ................................................................................ 13
MODES OF OPERATION .............................................................................................................. 14
LOCAL CONTROL ........................................................................................................................ 15
ISOLATION OF POWER SOURCES ............................................................................................... 16
STORED ENERGY ....................................................................................................................... 16
EMERGENCY MOVEMENT ........................................................................................................... 17
PERFORMANCE OF THE SAFETYRELATED PARTS OF THE CONTROL SYSTEM ....................... 17
CONTROL SYSTEM RESET.......................................................................................................... 17
SYSTEM STARTING/RESTARTING ............................................................................................... 17
EMERGENCY STOP ..................................................................................................................... 18
FLUID IMPACT ON OPERATING ENVIRONMENT AND EQUIPMENT .............................................. 18
MECHANICAL EQUIPMENT REQUIREMENTS ............................................................................... 19
SAFEGUARDING DESIGN REQUIREMENTS ................................................................................. 20
EJECTED PARTS OR FLUIDS ....................................................................................................... 20
VIEWING WINDOWS .................................................................................................................... 20
STRUCTURAL INTEGRITY ........................................................................................................... 20
NOISE ......................................................................................................................................... 20
ERGONOMIC CONSIDERATIONS ................................................................................................. 21
ERRORS OF FITTING................................................................................................................... 21
LIFTING OF SYSTEM COMPONENTS ........................................................................................... 21
DOCUMENTATION REQUIREMENTS............................................................................................ 21
LAYOUT, INSTALLATION, AND VALIDATION............................................................................... 22

7.1
7.2
7.3
GENERAL .................................................................................................................................... 22
LAYOUT AND INSTALLATION ....................................................................................................... 22
VALIDATION ................................................................................................................................ 23
iii
SAFEGUARDING.............................................................................................................................. 24
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
8.11
GENERAL .................................................................................................................................... 24
SAFEGUARDING REQUIREMENTS .............................................................................................. 24
GUARDS ...................................................................................................................................... 25
SAFEGUARDING DEVICES .......................................................................................................... 26
AWARENESS BARRIERS AND DEVICES ...................................................................................... 26
SAFEGUARDING AGAINST SPECIFIC HAZARDS .......................................................................... 26
SAFE WORK PROCEDURES ........................................................................................................ 27
PERFORMANCE OF THE SAFETYRELATED FUNCTION(S) ........................................................ 27
SAFETY RELATED SPAN OF CONTROL ....................................................................................... 28
MUTING ....................................................................................................................................... 28
SAFETY RELATED SYSTEM RESET ............................................................................................. 28
SETUP, OPERATION AND MAINTENANCE................................................................................. 30

9.1
9.2
9.3
9.4
9.5
9.6
GENERAL .................................................................................................................................... 30
SETUP ....................................................................................................................................... 30
OPERATION ................................................................................................................................ 30
MAINTENANCE ............................................................................................................................ 30
PERSONAL PROTECTIVE EQUIPMENT ........................................................................................ 30
TRAINING .................................................................................................................................... 31
ANNEX A - ILLUSTRATIVE EXAMPLES OF INTEGRATED MANUFACTURING SYSTEMS........... 32

ANNEX B - EXAMPLES OF HAZARDS, TASKS, AND TASK/HAZARD PAIR LISTS GENERATED BY
AN INTEGRATED MANUFACTURING SYSTEM RISK ASSESSMENT................................................ 35
ANNEX C - PERFORMANCE OF THE SAFETY-RELATED FUNCTION(S)....................................... 39
ANNEX D - SAFETY RELATED SPAN OF CONTROL EXAMPLES WITHIN AN IMS........................ 40
ANNEX E - ZONE DETERMINATION.................................................................................................... 43
iv
FOREWORD (This Foreword is not part of the requirements of American National

Standard B11.20-2004)
The primary objective of this standard is to eliminate or control hazards to personnel associated with
integrated manufacturing systems by establishing requirements for the construction, operation and
maintenance of these machines. To accomplish this objective, responsibilities have been assigned to the
supplier (e.g., manufacturer, rebuilder, reconstructor, installer, integrator), the user, and personnel in the
working environment.
The words "safe" and "safety" are not absolutes. Safety begins with good design. While the goal of this
standard is to eliminate injuries, it is recognized that risk factors cannot be practically reduced to zero in
any human activity. This standard is not intended to replace good judgment and personal responsibility.
Operator skill, attitude, training, job monotony, fatigue and experience are safety factors that must be
considered by the user.
This standard reflects the most commonly used and time-tested state of the art at the time of its approval.
The inclusion or omission of language relative to any evolving technology, either in the requirements or
explanatory area of this standard, in no way infers acceptance or rejection of such technologies.
Inquiries with respect to the application or the substantive requirements of this standard and suggestions
for its improvement are welcomed, and should be sent to the AMT The Association For Manufacturing
Technology, 7901 Westpark Drive, McLean, Virginia 22102-4206, Attention: B11 Secretariat.
Effective Date
The following is informative guidance only, and not a normative part of this standard. This Subcommittee
recognizes that some period of time after the approval date on the title page of this document is
necessary for suppliers and users to develop new designs, or modify existing designs or manufacturing
processes in order to incorporate the new or revised requirements of this standard into their product
development or production system.
This Subcommittee recommends that suppliers complete and implement design changes for new
machines within 30 months of the approval of this standard.
For existing or modified machines, this subcommittee recommends that users should confirm that the
equipment / process has tolerable risk using generally recognized risk assessment methods within 30
months of the approval of this standard. If the risk assessment shows that modification(s) is necessary,
refer to the requirements of this standard to implement protective measures for appropriate risk reduction.
This standard was processed and submitted for ANSI approval by the B11 Accredited Standards
Committee on Safety Standards for Machine Tools. Committee approval of this standard does not
necessarily imply that all committee members voted for its approval. At the time this document was
approved as an American National Standard, the ANSI B11 Accredited Standards Committee was
composed of the following member organizations:
John W. Russell, PE, CSP Chairman
Gary D. Kopps, Vice-Chairman
David A. Felinski, Secretary
Organizations Represented
Aerospace Industries Association of America
Alliance of American Insurers
American Institute for Steel Construction
American Society of Safety Engineers
AMT- The Association For Manufacturing Technology
Automotive Industry Action Group
Boeing
Can Manufacturers Institute
General Motors Corporation
John Deere
Metal Building Manufacturers Association
Metal Powder Industries Federation
Name of Representative
Delegate
Willard J. Wood
John Russell, PE, CSP
Thomas Schlafly
Bruce Main, PE, CSP
Russell Bensman
Ron Tillinger
Robert J. Eaker, PE, CSP
Geoffrey Cullen
Michael Taubitz
Gary Kopps
Charles M. Stockinger
Dennis Cloutier, CSP
Alternate
Robert J. Eaker, PE, CSP
Keith Lessner
George Karosas, PE, CSP
Willard J. Wood
Ellen K. Blanshan
Charles E. Praeger
Teresa F. Stillman
v
Natl. Inst. for Occupational Safety & Health

Occupational Safety & Health Administration
Packaging Machinery Manufacturers Institute
Precision Metalforming Association
Presence Sensing Device Manufact. Assn.
Robotic Industries Association
Scientific Technologies, Inc.
Sheet Metal & Air Conditioning Contractors Natl. Assn.
Tooling and Manufacturing Association
Toyota Motor Manufacturing North America
John Etherton, PhD

Ken Stevanus
Charles F. Hayes
William Gaskin
Jim Kirton
Jeff Fryman
Frank Webster
Mike McCullion, CSP
Daniel Kiraly
Barry Boggs
Christie Carmigiano
Mike Carlson
Chris Soranno
Allan Te Ronde
Tom Huff
At the time this standard was approved, the ANSI B11 ASC B11.20 Subcommittee had
the following members who participated in the development of this revision:
Steve Dukich
Rockwell Automation
Chairman
Mike Crampton
General Motors
Secretary
Don Lawson
Pilz
Chairman (3/01 2/02)
Blake Consdorf
Wes-Tech
Chairman (3/02 9/02)
John Bloodgood, PE
JFB Enterprises
Barry Boggs
Toyota Motor Manufacturing, NA
Sam Boytor
Fox Controls
Lee Burk
Pilz
Mike Carlson
Banner Engineering
Howard DeWees
SICK, Inc.
Brian Eggleston
Heinz Knackstedt
C & E Sales
Gary Kopps
Deere & Company
Ralph Lamkin
Lovejoy
Tom Levitt
Levitt & Associates
Marshall Lovelace
Stuart C. Irby Company
Bruce Main, PE, CSP
design safety engineering
Sam Mazzara
Ford Motor Company
Larry Morel
Delphi
Greg Motorojescu
Cross Huller
Lou Schubert
Scientific Technologies Inc.
Roberta Nelson Shea
Honeywell
Chris Soranno
STI Machine Services, Inc.
Steve Stevens
Cross Huller
Mike Taubitz
General Motors Corporation
Eric Thomas
Greg Todd
DaimlerChrysler Corporation
Tony Bratkovich, PE
AMT
vi
Explanation of
the format, and
ANSI B11
conventions
This ANSI B11.20 2004 standard is divided into parts

formerly referred to as sections or chapters and now
referred to as clauses in line with the current ANSI style
manual. Major divisions of clauses are referred to as
subclauses and, when referenced by other text in the
standard, are denoted by the subclause number (e.g., see
5.1).
The standard uses a two-column format to provide
supporting information for requirements. The material in
the left column is confined to Standard Requirements
only, and is so captioned. The right column, captioned
"Explanatory Information" contains information that the
writing Subcommittee believed would help to clarify the
requirements contained in the standard. This column
should not be construed as being a part of the
requirements of this American National Standard.
As in all American National Standards, the term SHALL
denotes a requirement that is to be strictly followed in order
to conform to this standard; no deviation is permitted. The
term SHOULD denotes a recommendation, a practice or
condition among several alternatives, or a preferred
method or course of action.
Similarly, the term CAN denotes a possibility, ability or
capability, whether physical or causal, and the term MAY
denotes a permissible course of action within the limits of
the standard.
B11 conventions: Operating rules (safe practices) are not
included in either column of this standard unless they are
of such nature as to be vital safety requirements, equal in
weight to other requirements, or guides to assist in
compliance with the standard. The B11 standards do not
use the term and/or but instead, the term OR is used as
an inclusive disjunction, meaning one or the other or both.
A distinction between the terms individual and
personnel is drawn.
Individual includes personnel
(employees, subcontractors, consultants, or other contract
workers under the indirect control of the supplier or user)
but also encompasses persons who are not under the
direct or indirect control of the supplier or user (e.g.,
visitors, vendors, etc.). Gauge refers to a measuring or
testing instrument; gage refers to limiting device (e.g.,
backgage).
Suggestions for improvement of this standard will be
welcome. They should be sent to AMT-The Association
For Manufacturing Technology, 7901 Westpark Drive,
McLean, VA 22102 - Attention: B11 Secretariat.
vii

Introduction
The primary purpose of every machine tool is to process parts. During production, maintenance,
commissioning and de-commissioning, hazards exist that may result in injury.
The primary purpose of the ANSI B11 series of machine tool safety standards is to devise and propose
ways to minimize risks of the potential hazards. This can be accomplished either by an appropriate
machine design, by restricting personnel or other individuals access to hazard areas, and by devising
work procedures to minimize personnel exposure to hazardous situations.
The responsibility for the alleviation of these risks is divided between the equipment supplier, the
equipment user and its operating personnel, as follows (numbers in parentheses refer to the clause
numbers in these standards which address that responsibility):
USER
SUPPLIER
PERSONNEL
Responsible for:
Instruction manual
Operation manual
Maintenance manual
(4.1)
Overall workplace safety

Maintenance and inspection procedures
Training
(4.2)
Comply with
instructions
(4.3)
Task and hazard

identification (5.1)
Risk assessment/risk
reduction (5.2)
For task/hazard combinations
for which the standard does not
provide protective measures,
apply the principles of B11.TR3
Design and construction (6)
Layout, installation, testing

and start-up (7)
NFPA 79
Safeguarding (8)
B11.19
Set-up, operation and

maintenance (9)
viii
AMERICAN NATIONAL STANDARD
B11.202004
American National Standard for Machine Tools
Safety Requirements for Integrated Manufacturing

Systems
STANDARDS REQUIREMENTS
EXPLANATORY INFORMATION
(Not part of the requirements of this American National
Standard for Machine Tools Safety requirements for
Integrated Manufacturing Systems.)
Scope
1.1
General
E1.1
This American National Standard specifies the safety

requirements for the design, construction, set-up, operation
and maintenance (including installation, dismantling and
transport) of integrated manufacturing systems.
The terms integrated manufacturing system, and

integrated manufacturing cell should be considered
as synonymous. This may also be known as a
flexible manufacturing system.
An integrated manufacturing system:

a) incorporates two or more industrial machines, at least one
of which is a machine tool;
b) is linked by a material handling system;
c) is interconnected with and coordinated by a control
system;
d) is capable of being re-programmed, re-configured or resequenced for the manufacturing of a variety of discrete
parts or assemblies.
Integrated manufacturing systems may be comprised

of two or more zones, each with their own individual
controls.
Zones segment the integrated manufacturing system
into manageable sections with defined purposes.
See also, Annex D.
See Annex A for
manufacturing systems.
examples
of
integrated
An integrated manufacturing system shall be designed and

safeguarded to ensure proper and safe operation and
maintenance in accordance with the risk assessment (see
Clause 5).
1.2
Exclusions
E1.2
This standard does not cover:

a) safety aspects of individual machines and equipment that
may be covered by standards specific to those machines
and equipment (B11 base standard);
NOTE: See inside cover of this standard for a list of the B11
base standards.
a) Where machines and equipment of an

integrated manufacturing system are operated
separately or individually, the relevant B11
safety standards for these specific machines
and related equipment should apply.
b) transfer machines or transfer lines;
b) See ANSI B11.24.
c) continuous flow processes.
c) Examples of continuous flow processes include

but are not limited to:
petrochemical;
food/beverage processing;
textiles;
rubber;
pulp and paper;
metal refining;
printing.
1
B11.202004
STANDARD REQUIREMENTS
Normative references
E2 Informative References
The following normative documents contain provisions that, The documents listed below contain information and
through reference in this text, constitute provisions of this guidance for implementation of the requirements of
American National Standard. At the time of publication, the this standard. They are included for information only.
editions indicated were valid. All documents in this clause
are subject to revision, and parties to agreements subject to
this American National Standard should apply the most
recent editions of the documents listed below, unless a
revision of a normative reference below published after the
approval date of this standard contradicts what is required in
this standard.
ANSI / ASSE Z244.1-2003, Control of Hazardous Energy Lockout/Tagout and Alternative Methods
ANSI / NFPA 79-2002, Electrical Standard for Industrial
Machinery
ANSI / NFPA 702002, The National Electrical Code
ANSI / NFPA-70E-2000, Electrical Safety Requirements for
Employee Workplaces
ANSI / ASME B15.1-2000, Mechanical Power Transmission
Apparatus
ANSI / IES-RP-7-1991, Industrial Lighting
ANSI A14.3-2002, Safety requirements for fixed ladders
ANSI A1264.1-2002, Safety requirements for industrial fixed
stairs; floor and wall openings, and industrial railings and
toe boards
ANSI B11.19-2003, Performance Criteria for Safeguarding
29 CFR 1910.147, Control of hazardous energy
(Lockout/Tagout).
For more information, go to
www.osha.gov
29 CFR 1910.333 (b), Selection and Use of Electrical
Work Practices. For more information, go to
www.osha.gov
ANSI B11.TR12004 Ergonomic Guidelines for the
Design, Installation and Use of Machine Tools
ANSI B11.TR21997 Mist Control Considerations for
the Design, Installation and Use of Machine Tools
Using Metalworking Fluids
ANSI B11.TR32000 Risk Assessment and Risk
Reduction A Guide to Estimate, Evaluate and
Reduce Risks Associated with Machine Tools
ANSI B11.TR42004 Selection of Programmable
Electronic Systems (PES/PLC) When Applied to
Machine Tools
ANSI / ASME B56.5-1993, Safety Standard for Guided
Industrial Vehicles and Automation Functions of
Manned Industrial Vehicles
2
B11.202004
ANSI / ASME B20.1-2000, Safety Standard for
Conveyors and Related Equipment
<Revision currently out for vote ends 8/4/03>
ANSI / ASME B30.13c-1999, Safety standard for
automatic storage / retrieval machines and associated
equipment
ANSI / RIA R15.06-1999, Industrial Robots and Robot
Systems -- Safety Requirements
ISO 11161-1994: Safety of machinery Integrated
manufacturing systems Basic requirements
NOTE A substantive revision of this standard was at
the DIS stage at the time of B11.20 approval. A final
ISO standard is expected sometime late 2005 or early
2006.
ANSI / IEEE 518-1982, IEEE Guide for the Installation
of Electrical Equipment to Minimize Electrical Noise
Inputs to Controllers from External Sources
ANSI Z535.1 2002 Safety Color Code
ANSI Z535.3 2002 Criteria for Safety Symbols
ANSI Z535.4 2002 Product Safety Signs and Labels
NMTBA (AMT) Noise Measurement Techniques
1976. NOTE: At the time of approval of B11.20-2003,
this voluntary industry standard was being updated
and revised as B11.TR5. Expected ANSI registration
as a new Technical Report is late 2005.
Organization
Resources
Counselors
(ORC)
Management of the Metal Removal Fluid Environment:
A Guide to the Safe and Efficient Use of Metal
Removal Fluids (www.orc-dc.org)
Metalworking Fluids:
Safety and Health Best
Practices
Manual.
OSHA
(www.oshaslc.gov/SLTC/metalworkingfluids).
Main, B.; Risk Assessment: basics and benchmarks;
dse, 2004 (www.designsafe.com).
Definitions
For the purposes of this standard, the following definitions

apply.
3.1
awareness barrier: An awareness device that
warns individuals by means of physical contact.
3.2
awareness device: A barrier, signal or sign that E3.2
warns individuals of an impending, approaching or present
hazard.
3.3
See also, ANSI Z535.1, Z535.3 and Z535.4.
barrier: A physical boundary to a hazard.
3.4
bypass: The suspension of a safety related
function of the control system or safeguarding device.
E3.4
For the purposes of this standard, a bypass
refers to the safety related functions and not to
process-oriented operating modes.
3
B11.202004
3.5
complementary equipment: Devices used to
ensure or augment the proper operation of the
safeguarding.
E3.5
Examples include devices such as safety
blocks, stopping performance monitors, and hand
tools. For more information, see clause 12 of ANSI
B11.19.
3.6
concurrent: Acting in conjunction; used to
describe a situation where two or more controls exist in an
operated condition at the same time but not necessarily
simultaneously.
3.7
control reliability: The capability of the
machine control system, the safeguarding, other control
components and related interfacing to achieve a safe state
in the event of a failure within their safety related functions.
E3.7
See also, safety related function.
3.8
control system: Sensors, manual input and
mode selection elements, interlocked and decision making
circuitry, and output elements to the operating devices or
mechanisms.
3.9
cycle: A complete movement from an initial
start position back to the same start position of the
industrial machine or system; the movement may include
loading and unloading.
3.10
discrete parts or assemblies: Separate or
distinct units or elements which are considered as the
output or work in process of an industrial machine or
system.
3.11
emergency stop:
A control that, when
actuated, initiates immediate or controlled stopping action
of hazardous motion of the system.
3.13
enabling device: A manually operated device
which when continuously activated, permits motion.
3.14
ensure: To establish, maintain, and monitor an
effective program, procedure or system to implement the
requirements of this standard
3.15
external [remote] control: A control mode
where the system or its machines and related equipment
are controlled from a location usually external to the
system.
3.16
fixed barrier guard: A guard affixed to a fixed
surface in such a manner so as to enclose all or part of the
hazard area.
3.17
fixture: A means used to locate or support
material or workpieces or tools [tooling] during operation.
E3.17 Examples of fixtures are universal tables,

angle plates, trunnions, rotating tables, and other
removable workholding equipment.
3.18
guard: A barrier that is designed and installed to
prevent entry into a hazard area.
3.19
harm: Physical injury or damage to health of
individuals.
3.20
E3.19 Harm may be a result of direct interaction

with the integrated manufacturing system or indirectly
as a result of damage to property or to the
environment.
hazard: A potential source of harm.
4
B11.202004
3.21
hazard zone (area): Space in which an
immediate or impending hazard exists.
3.22
hazardous motion: Motion of equipment or
release of energy that can present a hazard.
3.23
hazardous situation: A circumstance in which
an individual is exposed to a hazard(s).
E3.23 A hazardous situation is also referred to as a

task/hazard pair (combination).
The exposure can result in harm immediately or over
a period of time.
3.24
immediate stop command: A command that
initiates an action(s) to stop a hazardous motion (or
situation) at any point in the system cycle.
3.25
individual: A particular human being.
3.26
installer:
safeguarding.
the
E3.26
See also, supplier.
3.28
integrator: A supplier who applies or installs
safeguarding,
safety-related
control
interfaces,
interconnections or the safety-related functions of the
control system into a machine production system.
E3.28
See also, supplier.
E3.33
See also, supplier.
3.27
supplier
who
installs
E3.25 For the purposes of this standard, a

distinction between individual and personnel is drawn.
Individual includes personnel but also encompasses
persons who are not under direct or indirect control of
the supplier or user (e.g., visitors, vendors, etc.). See
also, personnel.
integrated manufacturing system: See 1.1.
3.29
interlock:
A means to permit or prevent
hazardous motion or conditions.
3.30
interlocked barrier guard: A fixed or movable
barrier or section of a barrier provided with an interlock
arranged to prevent entry into the hazard area [zone] when
the barrier or the section of the barrier is in the closed
position.
3.31
local control: A means that provides the
operator with direct and exclusive control of a specific
piece of equipment or zone.
3.32
lockout/tagout: The placement of a lock, tag
or both on the energy isolating device (e.g. disconnecting
means) in the de-energized condition indicating that the
energy isolating device or the equipment being controlled
shall not be operated until the removal of the lock/tag.
3.33
manufacturer:
A supplier that designs,
manufactures or assembles machines or systems.
3.34
material handling system: A system which will
take parts from the load/unload area, deliver them to the
proper work station for processing and return them to a
load/unload area without human intervention.
3.35
mode: The state or condition of the control
system that allows specific operation of the system.
5
B11.202004
3.36
movable barrier device: A safeguarding device
arranged to enclose the hazard area before machine
motion can be initiated.
3.37
muting: The automatic temporary suspension
of any safety related function(s) of the control system or
safeguarding device.
3.38
normal stop command:
A command that
initiates an action(s) to stop motion(s) or situation(s) at the
end of a cycle or at other points required by the system
functions.
3.39
operator: An individual who performs production
work and who controls the machine.
3.40
operator's [control] station: The complement
of controls used by the operator to operate the system or
zone.
3.41
personnel: An individual or individuals who are
employed by the user and trained for a specific task(s).
E3.41
Personnel
includes
subcontractors,
consultants, or other contract workers under the
direct or indirect control of the supplier or user. Does
not include other individuals such as visitors,
vendors, etc. See individual.
3.42
presence sensing device:
A device that
creates a sensing field, area or plane to detect the
presence of an individual or object.
E3.42
3.43
protective measures: Any action or means
used to eliminate hazards or reduce risks.
E3.43 Protective measures can include but not be

limited to:
inherent design;
guards;
safeguarding devices and complementary

equipment;
awareness devices;
safeguarding methods;
safe work practices / procedures, training,

personal protective equipment or other
administrative controls;
warnings.
See E8.4.
3.44
readily accessible: Having the capability of
being reached quickly, without having to remove obstacles
or obstructions.
3.45
risk:
A combination of the probability of
occurrence of harm and the severity of that harm.
3.46
safeguarded space:
The three-dimensional
volume defined by the safeguarding.
3.47
safeguarding: Protection of personnel from
hazards by the use of guards, safeguarding devices,
awareness devices, safeguarding methods, or safe work
procedures.
3.48
safeguarding device: A device that detects or
prevents inadvertent access to a hazard.
E3.48
See clause 8.
6
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3.49
safety related function(s): That portion of the
control system or safeguarding device that eliminates
exposure to a hazardous situation or reduces risk to a
tolerable level.
3.50
safe
work
procedure:
Documented
instructions that describe how a task is to be performed.
3.51
set-up: The process of changing, replacing or
adjusting
the
integrated
manufacturing
system
components to perform the desired task(s)/function(s).
3.52
shield: A barrier used to keep chips or coolant(s)
within the system, or used to reduce the potential of tooling
parts or workpieces from being ejected from the system.
3.53
span of control: That predetermined portion of
an integrated manufacturing system under coordinated
control.
E3.53 The span of control is a term used to

conveniently describe that portion of the IMS
controlled by safeguarding devices, emergency stops,
enabling devices, or other similar devices.
3.54
supervised: A means or method whereby the
user exercises control of the operation of the system.
3.55
supplier: An entity that provides the entire IMS,
one or more machines, components, equipment, or
services for the safeguarding associated with the IMS.
E3.55
A supplier can be the manufacturer,
manufacturers agent, representative or distributor,
reseller, installer, modifier, rebuilder or integrator.
NOTE - The user is considered a supplier when the
user provides part or all of the products or services
(e.g., design, system integration, maintenance).
3.57
tolerable risk: Risk that is accepted for a given
task and hazard combination [hazardous situation]. The
risk reduction process is complete when protective
tolerable risk has been achieved for the identified
task/hazard combinations and the machine as a whole.
E3.57 Although not used in this standard, the

phrase acceptable risk is considered virtually
synonymous with the phrase tolerable risk. See
also, discussion at p.31 in Risk Assessment: basics
and benchmarks; dse, 2004.
3.56
user: An entity that utilizes machines, systems,
and related equipment.
E3.56
When the user manufactures, installs,
modifies, rebuilds or integrates the safeguarding, the
user is considered the supplier.
3.57
zone: A segmented space within the integrated
manufacturing system.
E3.57 Zones are created to segment the integrated

manufacturing system into manageable sections with
defined purposes.
4
4.1
Responsibility
Supplier's responsibility
E4.1
The supplier shall be responsible for the design and

construction of those elements of the IMS that they
provide.
Contractual agreements should provide a clear

delineation of the specific goods and services
provided when multiple suppliers are involved.
4.1.1
The supplier shall design and construct those E4.1.1 The supplier should refer to clause 2 for
parts/portions of the IMS that they supply, in accordance applicable standards relative to the product or service
provided by that supplier. When safety standards are
with clauses 5, 6, and 8 of this standard.
not provided, safeguarding techniques used on similar
equipment should be applied to this type of
equipment, where applicable.
7
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The supplier shall identify the sources of hazards (see 5.1).
The supplier should work in conjunction with the user

to identify the task/hazard combinations (see ANSI
B11.TR3).
4.1.2
The supplier shall eliminate or provide the means
for controlling the identified hazards by implementing a
hazard control strategy (see clause 5).
4.1.3
The supplier shall provide instructional material for E4.1.3 The system documentation should contain
installation, testing, set-up, operation, safeguarding, and the following:
a) A clear, comprehensive description of the
maintenance of the system.
system and its installation including:
foundation
requirements
(e.g.,
space
allocation, dynamic loading);
power consumption requirements;
equipment layout;
major component weights;
work area safeguarding;
preparation prior to start-up;
energy sources;
dynamic (power on) set-up methods;
procedures for transporting and lifting,
erection, commissioning and
decommissioning;
b) The system performance specifications;
c) Physical environment requirements (e.g.,
lighting, vibration, noise levels, airborne
contaminants);
d) Information on the:
programming;
operation;
frequency of inspection.
e) Frequency and method of functional testing;
f) Guidance on the repair and maintenance of the
system and its safeguards.
4.1.4
Each supplier shall provide documentation for the
equipment they provide. The system integrator shall ensure
that the documentation provided is coordinated and relevant
to the entire system (see 6.23).
4.1.5
The supplier(s) shall be responsible for providing
means of isolating or dissipating stored energy associated
with the system.
4.2
User's Responsibility
4.2.1
The user shall be responsible for the overall
workplace safety of personnel. The user shall review the
system and its associated equipment including installation
and set-up and any modifications as provided by the
supplier(s) to ensure their compliance with clauses 5, 7, 8
and 9 of this standard.
E4.2.1 Users should consult the supplier's

instructional material regarding the unpacking,
handling, installation, operation and maintenance
including safeguarding of the system.
The user should provide, or require others to provide,
the necessary safeguarding.
E4.2.2
4.2.2 The user shall ensure that:
a) One method that may be used to identify
a) Hazards are identified for the tasks to be performed on
hazards and establish a hazard control strategy
the system (see 5.1);
is to form a team of individuals from the various
disciplines involved with the design, construction,
set-up, operation and maintenance of the
system.
b) The protective measures required for the tasks
identified in 4.2.1 (a) are provided and used in
accordance with clause 8 (see 5.2);
8
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c) The safeguarding required to eliminate or control the

identified hazards is used and maintained in
accordance with clause 8 of this standard (see 5.2);
d) A procedure for the inspection and maintenance of the
system is established to ensure that the system
safeguarding and all other protective devices are in
safe operating condition and adjustment;
e) Correct and safe work procedures are followed.
4.2.3
The user shall provide parameters to the supplier
such as production rate, quality and inspection
requirements, human interactions for maintenance and
operation, system efficiency requirements, available
physical space for the system, machine/system
reconfiguration requirements, services (e.g., power, water,
air, etc.) available, access locations, and noise level targets.
4.2.4
The user shall ensure that personnel who operate, E4.2.4 Some typical examples of instructions for
maintain, clean or perform other tasks associated with the system personnel might include, but not be limited to
system follow the instructions and directions to meet the the following.
requirements of this standard.
Personnel should:
Follow all safety practices and procedures

derived by conformance to this standard that
apply to their actions and conduct;
Notify the supervisor when they observe an

unsafe practice or condition;
Properly use all personal protective equipment

as specified by their user;
Install, position, or adjust safety devices as

instructed by the user under the provisions of
this standard;
Maintain an orderly work area.

Particular
attention should be given to the storage of tools
or parts that could be dislodged and fall, or roll;
Make a visual safety check of the set-up during

each shift. Severe operating conditions should
require more frequent checking;
Clean spillage of coolants or other industrial

fluids in work areas to prevent slipping hazards.
Personnel should not:
Alter, remove, or disable any safety equipment

without the approval of the user;
Wear clothing or jewelry that will present a

hazard to their personal safety;
Slow or stop moving parts (e.g., spindle or

workpiece) by hand-gripping of the work-holding
device or the workpiece;
Improvise a braking device (e.g., pry bar, piece

of wood, etc.).
4.2.5
The user shall ensure that all set-up and E4.2.5 The following should be considered as
maintenance personnel and operators are trained to examples of training elements and should be
perform the functions for which they are responsible. The expanded as they apply to a particular condition:
training shall include the portions of this standard related to
the function, location and use of all controls;

their work (see clause 9).
a safe method for installing, removing, and

adjusting tooling;
the location and method for installation and

adjustment of all protective devices and guards,
and the use of safe work procedures;
9
B11.202004
the control strategy designed to eliminate or

reduce the identified hazards;
troubleshooting and repair.
4.2.6
The user shall determine what personal protective
equipment is required and shall train personnel and enforce
the use of the equipment.
4.2.7
The user shall establish and follow a lockout/tagout E4.2.7
procedure that will limit personnel to exposure from
unintended system motion that can cause injury during
repair, servicing, or set-up of systems in accordance with
ANSI / ASSE Z244.1.
4.3
Personnel responsibility
See also, 29 CFR 1910.147 and 1910.333.
E4.3
The users personnel shall comply with the instructions of Examples of the system operator's, helper's, or set-up
the supplier and the user concerning safe methods of person's responsibilities:
operation of the system.
Follow all safety practices and procedures given

in this standard that apply to his/her actions and
conduct;
Notify their supervisor when they observe an

Properly use all personal protective equipment

as specified by the user;
Install, position, or adjust safety devices as

instructed by the user under the provisions of
this standard;
Do not alter, remove, or disable any safety

equipment without the approval of the user;
Make a visual safety check of the set-up during

each shift. Severe operating conditions should
require more frequent checking;
Do not wear clothing or jewelry that will present

a hazard to their personal safety;
Maintain an orderly work area.

Particular
attention should be given to the storage of tools
or parts that could be dislodged and fall or roll;
Never slow or stop the spindle or workpiece by

hand-gripping of the workholding device or the
workpiece;
Never use an improvised braking device (e.g.,

pry-bar);
Work areas should be free of spillage of

industrial fluids to prevent slipping hazards.
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5
5.1
Hazard control
Task and hazard identification
E5.1
During system design, all task categories to be performed Task identification should take into account, but not be
within the system shall be considered during the limited to, the following task categories:
identification of task / hazard combinations.
packing and transportation;
unloading/unpacking;
The additional task / hazard combinations associated with
systems installation;
the operation of the individual components as an integrated
startup/commissioning;
system shall be reviewed.
set-up and tryout (debug);
operation (all modes);

The task / hazard combinations of the individual machine
part load/unload;
tools, material handling systems, robots, and other ancillary
tool change;
equipment shall be reviewed.
reconfiguration;
process control and monitoring;

The task / hazard identification process shall be
reconsidered if the system is reconfigured.
planned maintenance;
unplanned maintenance;
major repair;
Task identification shall take into account machine to
recovery from control failure;

machine, and machine to material handling system or
recovery from jam;

machine to other system component interfaces.
troubleshooting;
housekeeping;
disposal;
working around portions of the IMS that are in

different modes (e.g., set-up and try out, tool
change, observation, maintenance, repair,
trouble shooting, recovery from control failure).
For a more detailed discussion on task/hazard
combination identification, refer to ANSI B11.TR3.
For each of the task categories there may be many
tasks. Tasks are specific activities that relate to the
task category.
Each task category may have
numerous tasks associated with it. Examples of tasks
are:
changing a tool;
replacing a drive belt;
replacing a filter;
clearing chips, scrap or jams;
adjusting in-process gages.

For each of the above tasks, there may be numerous
hazards.
Examples of hazards and hazardous
situations
addressed
within
this
standard
(design/construction, installation, set-up, operation
and maintenance) are contained in Annex B.
In addition, reasonably foreseeable hazards not directly Following are some examples of reasonably
related to tasks shall be identified.
foreseeable hazards not related to tasks:
failure of a high-pressure hydraulic line;
bearing failure or bearing seizure;
failure of the structural components of the

system.
Tasks and associated hazards shall be identified and reassessed when necessary or whenever the system is
modified or the typical use of one or more of its individual
components is changed (see 5.2).
Each time the system is modified or its use is

changed, the tasks/hazards associated with the
modification or change should be identified and
reassessed (see 5.2).
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5.2
Risk assessment / risk reduction
E5.2
Risks associated with the task/hazard combinations

identified in 5.1, including reasonably foreseeable hazards
not directly related to tasks, shall be assessed and reduced
to a tolerable level by incorporating one or more of the
following protective measures, in hierarchical order:
a)
b)
eliminate or control hazard(s) by design;

control exposure to hazards by the use of guards
or safeguarding devices;
provide other safeguarding (e.g., awareness
barriers, awareness signals and safeguarding
methods);
implement administrative controls or other
protective measures (including safe work
procedures, preventive maintenance, training, retraining, personal protective equipment and
warning signs).
c)
d)
When performing risk reduction for task/hazard

combinations identified in 5.1, including reasonably
foreseeable hazards not directly related to tasks, the
requirements of clauses 6, 7, 8 and 9 shall be implemented.
Where possible and when necessary, the user, in

conjunction with the supplier, should ensure that the
task/hazard combinations and reasonably foreseeable
hazards not directly related to tasks identified in this
standard, and their associated protective measures
are appropriate for the system to which this standard
is being applied. For further information on risk
assessment, see ANSI B11.TR3.
For performing risk reduction on task/hazard

combinations and reasonably foreseeable hazards not
directly related to tasks that are not resolved by
applying clauses 6, 7, 8 and 9, see B11.TR3.
Tolerable risk shall be determined by evaluating the Zero risk does not exist and cannot be attained.
application of the protective measures against the following However, a good faith approach to risk assessment
and risk reduction should reduce risk to a tolerable
factors:
level. For further information on tolerable risk, see
B11.TR3.
Risk-reduction benefit is determined by estimating the
potential reduction in severity of harm or probability of
occurrence of harm. The type of protective measure
is determined by the nature of the task and associated
hazard(s) for the system under consideration.
Protective measures should be selected to provide the
desired degree of risk reduction.
risk-reduction benefit;
technological feasibility;
economic feasibility;
ergonomic impact;
productivity;
durability and maintainability;
usability.
Risk reduction is complete when the protective measures,

consistent with this standard, are applied and tolerable risk
has been achieved for the identified task/hazard
combinations and system as a whole.
12
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6
6.1
Design and construction

General
E6.1
The following requirements apply to the control aspects

(e.g., electrical, hydraulic, pneumatic, mechanical) of
integrated manufacturing systems.
The system design shall take into account its use and
operation, not simply its working function(s).
Integrated manufacturing systems are often intended

to be flexible and re-configurable. The initial design
configuration should take into account the potential
for reconfiguration and consider the introduction of
new tasks and hazards.
The system shall be designed and constructed in such a

manner that risks are reduced to a tolerable level in
accordance with 5.2. This requirement applies:
a) to the interaction between a complete zone control
system and individual separated control systems
within the zone;
b) to individual control systems in relation to each other
within the zone;
c) where a system consists of a combination of sections
or single units from different suppliers.
6.2
Layout design requirements
E6.2
The design consideration of the layout of the IMS shall

include, but not be limited to:
a) Access and egress;
b) Work tasks and associated hazards;
c) Work flow;
d) Selection and application of safeguarding devices;
e) Span of control of the safeguarding devices;
f) Zones;
g) Physical space for air quality systems;
h) Physical space for pedestrian movement;
i) Physical space for stock movement;
j) Solid or liquid waste management.
6.3
Electrical equipment requirements
See local, state, or federal regulations that may

impact these requirements. See also, Annex E.
E6.3
The electrical equipment shall meet the requirements of

ANSI / NFPA 70, ANSI / NFPA 79, and ANSI / NFPA 70E.
ANSI / NFPA 70 specifies the requirements for the

interconnecting equipment (i.e., the wire, cable,
conduit, fittings and methods).
ANSI / NFPA 79 specifies the requirements for the
system or components, which are provided to
operate the integrated system.
ANSI / NFPA 70E addresses those electrical safety
requirements for the employee workplace that are
necessary for the practical safeguarding of
employees.
6.3.1
Grounding and shielding
The control system of the integrated manufacturing
system shall be protected against false operation due to
improper or accidental grounding or improper shielding.
E6.3.1
For further information on grounding and shielding,
reference ANSI / NFPA 79.
13
B11.202004
6.3.2
Interferences
The design and installation of the system shall incorporate
good engineering practices that protect controls and
control systems from sources of interference. If risks may
be foreseen as a result of interference, then separate
safeguards are required to ensure that interference with
control functions does not create hazards whenever the
system is put to its intended tasks.
E6.3.2
Examples of sources of interferences include:
a) electrical:
electromagnetic interference (EMI);
electrostatic discharge; (ESD);
radio frequency interference (RFI).

b) non electrical:
vibration/shock;
noise;
light;
radiation.
Electrical sources of interference are normally
associated with the operation of air conditioners;
electric welders; electric furnaces; elevators; high
energy power lines; radio frequency (RF), radar, or
microwave equipment; cellular phones; twoway
radios; electrostatic equipment; large brush type
motors or similar equipment. See ANSI / IEEE 518
and the recommendations of the manufacturer.
6.3.3
Fluctuation or interruption of power sources
Interruption or fluctuation in any of the power sources shall
not cause any hazardous situations or shall initiate an
immediate stopping action. Restoration of power by itself
shall not cause any hazardous situations or restart the
system.
6.4
Modes of operation
E6.4
Each integrated manufacturing system shall have

provisions for automatic and manual operating modes.
Different modes of operation are provided to allow

the safe performance of specific tasks (e.g.,
operation,
set-up,
troubleshooting,
and
maintenance).
Each system may have more than one automatic
mode and more than one manual mode.
6.4.1
Automatic mode(s)
During automatic mode, all protective measures shall be in
place and functioning properly.
E6.4.1
Automatic mode refers to normal operation, which
may also be referred to as automatic continuous,
automatic single cycle, or run mode.
6.4.2
Manual mode(s)
Manual modes shall:
a)
Be provided to allow for the safe performance of
manual tasks;
E6.4.2
b)
Provide safe access to perform the tasks in (a)

above (see also E6.4.2 a);
b) See also, clause 7;
c)
Be designed to reduce risk to a tolerable level for

certain specific task categories and their task/hazard
pairs (see 5.1 and clause 9);
a) Tasks during manual mode may include, but are

not limited to:
set-up;
teach;
jog;
adjustment;
testing;
maintenance;
recovery from jam;
troubleshooting;
cleaning.
14
B11.202004
d)
Include alternate protective measures when the

protective measures used during automatic mode
are bypassed;
e)
Be manually initiated;
f)
Prevent a hazardous situation from being remotely

initiated;
g)
Prevent the automatic entrance of external hazards

into the area(s).
d) Alternate protective measures may include, but

are not limited to:
Guards;
protective devices;
enabling pendants;
two hand controls;
safe work procedure or practice;
slow speed/torque;
portable emergency stop;
time-limiting
of
suspended
protective
measures.
g) Examples include:
automated guided vehicles;
other automatic material handling processes.
6.4.3
Mode design
The performance level of the safety function of each mode
shall be consistent with the risk assessment.
E6.4.3
A risk assessment shall determine which modes have

limited (lockable) access and how an individual selects the
mode.
Means for limiting access can include but are not

limited to:
key lock switch;
access codes;
interlocks;
gate access control(s);
captive / trapped key systems.
6.4.4
Mode Selection
The selection of the operating mode shall:
by itself, not generate hazardous situations;
require a separate deliberate action to initiate

operation;
automatically group operational capabilities with

protective measures;
be accomplished outside the hazard area;
be clearly indicated;
be indicated in a consistent manner.
E6.4.4
Mode selection is the process of changing the
operation of the system from one mode of operation
to another. This change may be from:
one automatic mode to another automatic

mode;
a automatic mode to a manual mode;
one manual mode to another manual mode;
a manual to an automatic mode.
6.5
Local control
E6.5
Local control, when required on a piece of equipment

within a system, shall meet the following conditions:
Indication of the operating mode may be by visual

display, indication light, position of a selection
switch, or other means.
Local control of equipment may be used while the

system is in an automatic or manual mode of
operation. The use of local control may be required
by:
risk assessment;
functional requirements;
maintenance needs.
Means for selecting local control shall be located

outside the hazard area;
Switching between local control and remote or
external control shall not in itself create a
hazardous situation;
15
B11.202004
Motion shall only be initiated at the local control

panel of the equipment;
Personnel should be trained in the proper use and

operation of the local control.
External hazards shall be prevented from entering

the area(s) under local control.
External hazards, such as automated guided

vehicles (AGVs), robots, conveyors and storage /
retrieval systems may be prevented from entry into
areas under local control by:
system design;
span of control;
safeguarding.
See also, ANSI: ASME B56.5; RIA R15.06; ASME
B20.1; and ASME B30.13c.
6.6
Isolation of power sources
E6.6
Means for isolating power sources shall be provided,

shall be marked or labeled to identify the power
source(s), and shall have lockout/tagout capability in
accordance with ANSI / ASSE Z244.1.
Power source monitors that initiate the stopping

action may be required.
6.6.1
Routine servicing and maintenance
Lockout/tagout is the primary method of hazardous energy
control. When the tasks identified in E6.4.2 a) are routine,
repetitive and integral to the production process, or
traditional lockout/tagout prohibits the completion of those
tasks, alternative methods of control that are based on the
risk assessment and that provide effective personal
protection shall be used.
E6.6.1
Tasks that are routine, repetitive and integral to
production generally exhibit most of the following
characteristics:
short in duration;
relatively minor in nature;
occur frequently during the shift, day or week;
usually performed by operators, set-up,

service or maintenance personnel;
do not involve extensive disassembly;
represent predetermined cyclical activities;
expected to occur regularly;
minimally interrupt the production process;
exist even when optimal operating levels are

achieved;
require task-specific personnel training.
Power source isolation can be determined after the

risk assessment. All energy isolation means for a
span of control should be located in a common area
or service center. For further information, reference
29 CFR 1910.147 and 1910.333.
6.6.2
Non-routine servicing and maintenance
When the tasks identified in E6.4.2 a) are not routine,
repetitive and integral to the production process, then
lockout/tagout shall be used per ANSI / ASSE Z244.1.
6.7
Stored energy
E6.7
Loss of power shall not result in a hazardous situation due

to the release of stored energy.
Some examples of stored energy are air or fluid

pressure,
gravity,
springs,
counter-balances,
flywheels, capacitors, and un-interruptible power
supplies.
16
B11.202004
Means shall be provided for the isolation, containment or

controlled release of stored energy that can create a
hazardous situation.
6.8
Emergency movement
Examples of isolation, containment or controlled

release of stored energy are:
blocking;
pinning;
chaining;
locking;
controlled bleeding;
check valves;
discharging;
dynamic braking;
mechanical braking;
power-down procedures.
E6.8
Means shall be provided to enable movement of the

system elements under emergency conditions.
These movements should be determined by the risk

assessment (see clause 5).
a) With power off:
Venting of relief valves to depressurize
systems under pressure;
Manual release of mechanically-actuated
brakes provided that additional hazards are
not created.
b) With power on:
Manual control facilities of power-piloted
valves/drives;
Control facilities to start counter motions.
6.9
Performance of the safetyrelated parts
of the control system
When required by the risk assessment, the safety related
parts of the control system shall meet the requirements of
8.8.
6.10
Control system reset
E6.10
A prescribed procedure shall be used to reset the control

system.
The control system reset can be separate or the

same as the safety system reset.
The control system shall be manually reset before initiation

of hazardous motion.
The action of resetting the control system shall not cause
initiation of hazardous motion.
The control system reset device shall be located outside
the safeguarded space.
The safety system(s) shall be reset prior to the control
system reset.
See 8.11 for safety system reset
requirements.
6.11
System starting/restarting
E6.11
Start/restart shall require an intentional action from a

control station located outside the safeguarded space.
Impending start-up may be indicated through use of

an awareness device, as suggested by the risk
assessment or existing practices within a particular
workplace.
Start/restart of the zone shall be located within clear and

unobstructed view of the safeguarded space. Where this is
impractical, additional means to ensure that the zone is
clear of individuals shall be implemented per the
requirements of 8.11.
Unexpected or sudden motion of a portion of the

system can result in injury to the operator due to
reflexive reaction (startle) causing falls or
unintended movement into some other hazard.
17
B11.202004
When it is required that the system (or a particular zone) be

started concurrently from several control points, these
starting means shall be interlocked to prevent starting from
less than the required number of control points.
When a zone is to be started from a single point of control,
the system shall prevent starting of that zone from other
locations.
6.12
Emergency stop
E6.12
The need for emergency stop functions and devices for the
entire system or zones shall be based on risk assessment.
See 8.9.
Individual emergency stop functions or devices for

each zone are not automatically required. The
supplier or user should decide if this type of control
is necessary by performing a risk assessment. See
ANSI B11.TR3.
The emergency stop shall conform to ANSI / NFPA 79.
An emergency stop is not a safeguarding device. It

is only intended for immediate cessation of a
hazardous condition or situation.
Retention of power on certain portions of the system
may be necessary to prevent hazardous motion, to
maintain program logic, or to provide braking during
emergency stopping.
See also, Figures D.1, D.2 and D.3 in Annex D.
6.12.1 Emergency stop function

There shall be only one emergency stop function for each
span of control.
E6.12.1
The emergency stop function can be accomplished
by one or more emergency stop device(s).
Stopping action of hazardous motion may take
different forms due to the variety of systems and
related equipment utilized in a system.
Hazards existing after the execution of an emergency stop

function shall be controlled.
A risk assessment should be conducted to

determine if hazards remain after the execution of
the emergency stop function. See clause 5 and
B11.TR3 for further information.
6.12.2 Emergency stop devices

The emergency stop device(s) shall be readily accessible.
E6.12.2
Readily accessible means the capability of being
reached quickly, without having to remove obstacles
or obstructions.
6.12.3 Recovery from emergency stop

The system shall be designed to enable recovery from an
emergency stop without creating a hazard.
E6.12.3
See also, 6.8.
6.13
Fluid impact on operating environment
and equipment
E6.13
Interaction between fluids within the system or between

the system and the outside environment shall not create a
hazard. The design or construction of new or existing
systems that incorporate machine tools and other
equipment requiring fluid systems shall control the
following potential hazards:
Systems that incorporate machine tools and other

equipment requiring various fluid systems (i.e.,
different fluid types, e.g., aqueous and synthetic
metal removal fluids), may have additional potential
hazards beyond those covered by the individual
base machine tool safety standard (see inside
cover for the list).
a) Magnesium machining near aqueous systems.
a) Interaction of wet machining processes with dry

machining processes;
b) Inter-machine fluid containment/recovery (not just
intra-machine);
c) Impact(s) on operating environment and equipment;
18
B11.202004
d) Fire hazard.
d) Misting and accumulation of machining fluids

(particularly straight oils or kerosene used in
some aluminum processes) in conjunction with
heat/arc producing equipment may produce a
fire hazard.
When different fluids are used in the system, provisions

shall be made to ensure that no adverse impacts occur as
a result of cross contamination.
The use of shields is one means to minimize
splashing during operation. See also, ANSI B11.19
and B11.TR2.
Comprehensive and informative guidance on the
total management of metal removal fluid systems
can be downloaded from Organization Resources
Counselors, or OSHA (see clause E2).
6.14
Mechanical equipment requirements
Where practicable, the supplier shall eliminate the hazard

by design or provide protection against mechanical
equipment hazards.
6.14.1
Power transmission components
The supplier shall conform to the requirements of ANSI /
ASME B15.1.
E6.14.1
Some of the hazards that might exist are the
following:
Rotating components, such as gears,

sheaves, and shafts in close proximity to
personnel;
Pinch points, such as meshing gears, belts,

and chains.
6.14.2
Powered moving parts
A powered moving part that constitutes a hazard to
personnel shall be safeguarded in accordance with 5.2.
E6.14.2
Some examples of hazards are:
pinch points between moving and stationary
components of the machine;
moving pallets.
6.14.3
Broken or falling machine components or
equipment
Machine components or equipment shall be designed,
secured, or covered to minimize the probability of
occurrence of harm to personnel in the event that the
component or equipment breaks, falls, or releases its
mechanical energy.
E6.14.3
Some of these hazards exist due to the merging or
integration of these machine components or
equipment.
6.14.4
Machine mounting
The machines shall be mounted and installed according to
supplier instructions.
6.14.5
Ladders, work platforms, and walkways
When required, ladders, work platforms, and walkways
shall be in accordance with ANSI A14.3.
Means of access (e.g., ladders, platforms, walkways) to
and within the integrated manufacturing system shall be
designed to minimize the likelihood of slips, trips, and falls
by provision of adequate hand holds, foot holds, and, where
necessary, by slip resistant surfaces. Design of the access
means shall take into consideration the potential for unsafe
interaction with mobile equipment traffic.
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6.14.6
Contact with high-temperature components or
surfaces
The supplier shall provide protection for machine operators
in the normal work area from coming into contact with
machine components whose surface temperatures may be
in excess of 70oC (160oF). The supplier shall also provide
protection for the operator(s) in normal work areas so that
s/he will not contact machine components at temperatures in
excess of 60oC (140oF) where reaction from contact can
result in an injury.
E6.14.6
6.14.7
Contact with sharp edges, corners, and
projections
The supplier shall design and construct the machine
components without exposed exterior sharp edges, corners,
and projections that can be hazardous.
E6.14.7
Edges or corners with less than 0.25 mm (0.01-inch)
radius are considered sharp. Particular attention
should be given to sheet metal panels, both edges
and cutouts.
6.15
E6.15
Inadvertent contact with a surface temperature in

excess of 60oC (140oF) can result in injury due to
physical burn or reflexive reaction causing falls or
unintended movement into a hazard.
EXCEPTION - Cutting tools are excluded from this requirement.
Safeguarding design requirements
The system shall be equipped with safeguarding to protect

against hazards. Safeguarding shall prevent access to the
hazard or reduce the risk to a tolerable level.
The
safeguarding for the system shall be in accordance with
clause 8.
6.16
Ejected parts or fluids
E6.16
Individuals shall be protected against ejected parts or fluids

by guards or shields, respectively, of sufficient strength to
contain these parts or fluids.
These guards or shields shall include means of fixing to the
machine or floor.
6.17
Viewing Windows
When safety guards or shields are equipped with viewing

windows, which are also intended to contain ejected parts,
consideration shall be given to the selection of materials and
the method of their installation.
6.18
General guidance for the design and construction of

safeguards is given in ANSI B11.19.
Some examples of ejected parts or fluids include but

are not limited to:
broken tools;
work material;
scrap or chips;
machine parts;
coolant.
Window materials (e.g., polycarbonate) which are
subject to impact resistance deterioration over time
(aging) due to contamination by lubricants, metal
removal fluids, solvents etc. may be protected by
external sheathing layers (e.g., safety glass, plastic
coating) and sealed on their periphery. See the
ANSI B11 base standard for further information.
Structural integrity
The system shall be designed to maintain structural integrity

throughout the full range of functions and dynamic motions,
taking into account the maximum workpiece size and weight
distribution.
6.19
Noise
E6.19
The supplier shall document the measured noise level.
The values should be measured in accordance with

NMTBA (AMT) noise measurement techniques. The
supplier and user may specify measurement
techniques or acceptance criteria.
Noise levels and resulting risks shall be considered when

designing the machine.
The following table presents some common primary

sources of machine or equipment noise (left column),
and corresponding examples of technical measures
for reducing that noise source (right column).
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B11.202004
a) transmission noise
b) pneumatic exhaust
c) power generation source
d) noise under cutting process
e) cutting tool change
f) workpiece change
6.20
gearbox damping
silencers
damping or
absorber
damping or
absorber inside the
hazard area;
enclosing guard
Ergonomic considerations
Provision shall be made to enable workpieces, tools or See also, ANSI B11.TR1.
fixtures to be loaded/unloaded without excessive effort or
adverse effects on health.
Means shall be provided to ensure safe operation by making
controls, observation and service points easily accessible.
Displays (e.g., visual display units, alarm annunciators,
indicator lights and the action-initiating icons of the humanmachine interface device) shall be clear and unambiguous.
6.21
Errors of fitting
Positive means shall be embodied in the design of system

parts to minimize the probability of errors of fitting (e.g., use
of male/female connections, asymmetrical location features)
or the system parts shall be marked in accordance with the
documentation.
6.22
Lifting of system components
E6.22
Where a lifting hazard has been established, identification of Lifting point identification can be eyebolt attachment
holes, permanent hook(s) or other suitable component
a lifting point on the load shall be provided.
features to which lifting equipment can be attached.
6.23
Documentation requirements
E6.23
The supplier shall provide documentation describing the Due to the wide variety of systems covered in this
integrated manufacturing system. The documentation shall standard, specific systems may require additional
contain, at a minimum, the following:
information, for example:
a) a clear, comprehensive description of the system and
function and location of all controls;

its installation including:
spindle speeds; horsepower; table speeds;

mounting and foundation requirements (e.g., space
length of travel of the slide or spindle, etc.;
allocation, dynamic loading);
maximum allowable size or weight of the cutting

connection to external energy sources;
tool and cutting-tool assembly;
power consumption requirements;
maximum recommended weight of workpiece

equipment layout including personnel access (e.g.,
and fixture;
stairs, walkways, crossovers, work platforms). See
safety instructions for personnel;

ANSI A1264.1;
lubrication
specification,
including
the access space needed by personnel for
recommended
lubricants,
frequency
of
lubrication, adjustment, chip removal, coolant
lubrication, and locations to be lubricated;
reservoir cleaning and similar routine activities;
electrical, hydraulic, lubrication, and pneumatic

major component weights;
diagrams;
work area safeguarding;
periodic maintenance instructions.

preparation prior to start-up;
procedures for transporting and lifting, erecting, and
commissioning.
b) consistency with the device markings found on the
system;
c) the system performance specifications;
d) external power source(s) specifications;
e) physical environment specifications (e.g., lighting,
vibration, noise levels, exhaust ventilation);
21
B11.202004
f) a description of potentially hazardous conditions and

how to avoid them;
g) hazardous energy control (isolation) diagram;
h) information on the:
programming;
operation;
frequency of monitoring and inspection;
frequency and method of functional testing;
maintenance of the system and its safeguards.

i) a description of the protective measures and the
hazards they control;
j) a description of the alternate protective measures used
when safeguards are bypassed;
k) manuals covering individual machines and equipment
within the system.
If the industrial machines and equipment are to be used This may describe necessary modifications to the
individually or as a group, additional documentation shall be safeguarding.
provided as to how to segregate and operate the zone.
If individual machines or equipment have been modified, the
documentation shall be updated to reflect such changes.
Layout, installation, and validation
7.1
General
E7.1
This clause describes the requirements for the layout,

installation, and validation of the system and its associated
equipment.
The user shall have a written plan for the installation of the The user should consider the process within which the
system will be utilized, and the movement of material
system and its associated equipment.
and individuals around and within the area of
placement. Applicable OSHA and building regulations
The installation shall conform to:
a) applicable local, state and federal regulations, or the should be consulted so sufficient lighting, and areas
for ingress, egress and material movement areas are
authority with jurisdiction;
available.
b) ANSI / NFPA 70;
c) ANSI / NFPA 70E;
A task-based risk assessment performed at this stage
d) ANSI / NFPA 79;
is often beneficial. See clause 5 and ANSI B11.TR3.
e) ANSI / ASSE Z244.1;
f) requirements or specifications from the supplier;
g) the requirements of this clause.
The layout area for the installation shall be evaluated to
ensure compatibility of the system with the expected tasks,
operating conditions, and access needs for the machine(s) /
zone(s) / system(s) and their reconfiguration.
7.2
Layout and installation
E7.2
user
should
consider
the
suppliers
The layout and installation shall meet the requirements of The
7.2.1 through 7.2.7 and shall enable the performance of all recommendations for the layout and installation. See
also, ANSI B11.TR1.
tasks identified in 5.1.
7.2.1
Evaluation of layout area
The layout area shall be evaluated to ensure functionality of
the IMS under expected operating conditions and
performance of tasks at a tolerable level of risk.
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B11.202004
7.2.2
Floor integrity
The flooring shall be capable of securing and bearing the
anticipated load of the system and its associated equipment.
E7.2.3
7.2.3
Space allocation
Equipment layout shall allow individuals access to and Examples of space allocation considerations for
egress from the system and its design configuration(s) for access and egress may include, but not be limited to:
operation, material handling and maintenance.
positioning of equipment and workplace

physical features to provide for maintenance;
arrangement of machinery and operator

interfaces to avoid blind corners;
traffic guide markings;
door swing;
access for major system reconfiguration;
portions of the system that can be used

independently.
Where practicable, maintenance elements (e.g., points of
lubrication, adjustment mechanisms) shall be located outside
the hazard area.
7.2.4
Lockout/tagout
Each installation shall have a means to disconnect or
isolate energy sources in accordance with ANSI / ASSE
Z244.1.
E7.2.4
Various means may be used to disconnect an
integrated manufacturing system from each type and
source of power. Clearly identified zones may be
disconnected separately.
See also, 29 CFR
1910.147 and 1910.333.
These means shall be readily accessible and shall not pose

a hazard to operate.
7.2.5
Lighting
Lighting shall be installed to ensure that personnel can safely
perform their tasks. For lighting requirements, see ANSI /
IES RP-7.
E7.2.5
The lighting should not create shadows, excessive
glare, or stroboscopic effects. The ease and means
for replacing lights should be evaluated.
7.3
E7.3
Validation
Validation of the protective measures shall be performed The purpose of validation is to ensure the proper
prior to the release of a new system for production and after installation, use and operation of the protective
measures.
any modification of an existing system.
Validation shall meet the requirements of 7.3.1 through 7.3.3.
E7.3.1
7.3.1
Validation procedures
The user shall ensure that a validation procedure is provided The user should use the supplier's recommendations
as a guideline in developing a start-up and testing
and used.
procedure.
The simulation of reasonably foreseeable failures
should be included in the initial validation or
modification of the safeguarding.
E7.3.2
7.3.2
Personnel restrictions
Only personnel with the appropriate skills, knowledge and Such personnel are often referred to as qualified or
safety training shall be allowed to operate the system and its authorized.
associated equipment during test and start-up.
E7.3.3
7.3.3
Safeguarding during validation
If the safeguarding is not functional during validation, other It is not always possible during validation to have all
safeguarding functional. This requirement is intended
protective measures shall be used (see also clause 8).
to ensure that alternate protective measures are used
If another protective measure(s) is used, exposed personnel and that personnel are aware of any increased risks.
shall be aware of its limitation(s).
23
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Safeguarding
8.1
General
E8.1
When individuals are exposed to hazards associated with an

industrial machine or other equipment within the system:
a) Safeguarding shall be provided in accordance with the
appropriate ANSI safety standard;
b) When a machine-specific safety standard does not

exist for the industrial machine or other associated
equipment within the system, a risk assessment shall
be performed and appropriate protective measures be
implemented to reduce risk for identified task/hazard
pairs to a tolerable level.
a) Where machines and equipment of an integrated

manufacturing system are operated separately
or individually, the relevant safety standards for
these machines and equipment should apply;
b) Specialized equipment or machinery may not be
covered by machine-specific safety standards.
Safeguarding techniques used on similar
equipment should be applied to this type of
equipment where applicable.
See ANSI
B11.TR3 for guidance on risk assessment and
risk reduction.
Where a hazard, either immediate or impending, exists, one Specific safeguarding requirements are found in
or more of the following shall be provided:
the machine-specific ANSI B11 (base) safety

1) Guards;
standard(s) (see inside cover for the list);
2) Safeguarding devices;
ANSI B11.19; and

3) Awareness devices;
ANSI / RIA R15.06.

4) Safeguarding methods;
5) Safe work procedures;
6) Complementary equipment.
The selected means of safeguarding shall be consistent with Selection of the safeguarding requires task and
hazard identification, and the application of risk
the identified hazards and their associated risks.
assessment and risk reduction of the total production
system.
For additional guidance on risk assessment and risk
reduction, see ANSI B11.TR3.
8.2
Safeguarding requirements
8.2.1
Safeguarding at the perimeter
The perimeter of the system or zone shall be defined or
marked.
Safeguarding shall be provided to prevent or detect
individuals reaching into or entering the hazard area.
Detection of entry shall prevent initiation or cause cessation
of the hazard(s) before individuals are exposed.
8.2.2
Safeguarding between individual machines
Where a hazard exists between individual machines,
transport/handling equipment or other components of the
system:
a) guards shall be provided to prevent individuals from
entering or reaching into a hazard area; or
b) safeguarding devices shall be provided to detect
individuals reaching into or entering a hazard area.
Detection shall prevent initiation of hazardous situations,
cause immediate stopping action of hazardous situations
within the hazard area or prevent individuals from entering
the hazard area.
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B11.202004
8.2.3
Safeguarding in production mode
System operation shall only be possible when the interlocked
movable guards are closed or the protective devices are
active.
The safeguarding shall be located at a distance from the
nearest hazard such that the individual cannot reach the
hazard before cessation of hazardous motion or situations.
E8.2.4
8.2.4
Safeguarding in manual mode
When a safeguard has been bypassed during the manual See also, clause 5 and ANSI B11.TR3.
mode, alternate safeguarding shall be required, as
determined by risk assessment.
8.2.5
Safeguarding during process observation
When process observation is required, and cannot be
performed from outside the safeguarded space, the supplier
or user shall implement a mode that:
a) reduces risk to a tolerable level using alternative
protective measures; and
b) provides access to a specific location for personnel to
make the observations.
8.3
E8.2.5
Where extended manual intervention is required for a
specific machine, that base standard should be used
to determine the appropriate operating modes and the
specific safety requirements relevant to each mode.
Guards
E8.3.1
8.3.1
General
Guards shall be designed and constructed in accordance Guards may include fixed and interlocked movable
guards.
with ANSI B11.19.
Guards shall meet the following design, construction,
application, and adjustment requirements:
a) Prevent entry of clothing or body parts into the
hazardous area(s) that it is guarding;
b) In itself, create no pinch points between the guard and Examples of additional protective measures include
moving system parts. Where pinch points cannot be the use of enabling devices, space markings, and
designed out, additional protective measures shall be safe work procedures.
provided.
c) Be mounted to minimize the possibility of misuse or
unintentional removal;
d) Facilitate its inspection; and
e) Offer maximum visibility of the hazard area consistent
with the above requirements.
8.3.2
Fixed guards
A fixed guard shall be kept in place (i.e., closed):
a) either permanently (by welding, etc.);
b) or by means of fasteners (e.g., screws, bolts) making
removal/opening impossible without using tools.
E8.3.2
A fixed guard is intended for situations that require
infrequent access (e.g., repair, maintenance, service).
8.3.3
Movable guards
Movable guards shall be interlocked so that:
a) the hazardous system functions protected by the guard
cannot operate until the guard is closed;
b) if the guard is opened while hazardous system
functions are operating, a stop for those hazardous
situations covered by the device shall be initiated (see
ANSI / NFPA 79).
E8.3.3
A movable guard is intended for situations that
require frequent access (e.g., during normal
production).
The closing of the guard shall not, by itself, initiate the

operation of the hazardous functions covered by the guard
(i.e., manual initiation shall be required).
25
B11.202004
8.4
Safeguarding devices
Safeguarding devices shall be designed, constructed, Safeguarding devices may include but need not be
limited to:
installed and operated in accordance with ANSI B11.19.
movable barrier devices;

If a hand or other part of the body is detected, a
pull-back (pull-out) and restraint devices;

safeguarding device shall:
electro-optical, RF, and area scanning presence

a) be interlocked into the control circuit to initiate a stop
sensing safeguarding devices;
(see ANSI / NFPA 79) for those hazardous situations
two-hand operating lever, trip and control

guarded by the device; or
devices;
b) prevent initiation of the hazardous function(s) guarded
safety mat devices;

by the device.
safety edge devices;
probe detection devices;
single control safeguarding devices.
8.5
Awareness barriers and devices
Awareness barriers and devices shall be designed,

constructed and located in accordance with ANSI B11.19.
8.6
Safeguarding against specific hazards
8.6.1
Power operated workholding hazard
When power operated workholding exposes the operator to a
pinch-point hazard, a protective device or guard shall be
provided.
E8.6.1
Where the clamp opening is 6 mm (1/4 inch) or less,
or the distance between the clamp and clamp control
is greater than the operator's reach, a guard or
protective device is not required.
8.6.2
Chip or coolant hazard
Chips and coolant shall be controlled by the use of a shield
or other means from being thrown or splashed onto an
operator, an aisle, or an assigned work area.
E8.6.2
When a shield or guard placed on a system for the
purpose of safeguarding against some other hazard
also effectively controls the chips and prevents
coolant or chips from being thrown onto the operator,
the work station, or other assigned work areas, then
further chip or coolant shielding is not required. The
shields specified herein are in no way intended to
replace the use of, or need for, eye or face protection.
8.6.2.1 Portable chip or coolant shields

One or more portable chip or coolant shields, either
transparent or nontransparent, may be used in lieu of
permanent chip shields where they are so placed and
consistently used as to effectively control the chips or
coolant.
E8.6.2.1
Portable chip or coolant shields, because they are
movable, should not be used as the sole means of
protecting against a tool or trappingspace hazard.
8.6.2.2 Chip removal

Chips that are in the process of being generated shall not be
handled by hand.
E8.6.2.2
Removal means by itself should not create a hazard.
8.6.2.3 Slip hazard

When it is necessary for the operator to step or walk on part
of the system that is wet with coolants or lubricants and
presents a potential slip hazard, a non-slip stepping
surface shall be provided.
E8.6.2.3
The design should not require the operator to step or
walk on parts of the system that could be wet with
coolant or lubricating oil.
EXCEPTION - Where these surfaces are workmounting or work

bearing surfaces, the use of leakproof and non-slip footwear is
acceptable.
8.6.3
Fluid contamination
When different fluids are used in the system, provisions shall
be made to ensure that no hazards occur as a result of
cross contamination.
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B11.202004
E8.6.4
8.6.4
Gages
System gaging procedures shall not expose the operator to Examples of hazards might be from chips or moving
components.
hazards.
E8.6.5
8.6.5
Workpiece loading device
Loading devices (e.g., cranes, hoists, shuttles, etc.) shall be Examples of hazards may be a process motion or the
inadvertent dropping of the workpiece that may result
safeguarded if they expose individuals to hazards.
in a trapping, nipping, crushing or shearing injury.
8.7
Safe work procedures
The use of safe work procedures shall protect personnel

from the hazards associated with setup, operation and
maintenance of the system by reducing the exposure to a
hazard(s).
The procedure used shall be appropriate for the task.
Changes in the work procedures or tasks shall not render
them ineffective. The user shall ensure that the operator is
properly trained in the use of the procedure and aware of the
hazards involved.
8.8
Performance of the safetyrelated
function(s)
E8.8
This subclause shall apply when referenced by other parts of

this standard.
When a component, module, device or system failure occurs,
such that it or a subsequent failure of another component,
module, device or system would lead to the inability of the
safety-related function(s) to respond to a normal stop
command or an immediate stop command, then the safetyrelated function shall:
Because some failures cannot be detected until the

completion of a cycle or a portion of the cycle, loss of
the safety-related function(s) may occur for a portion
of the machine cycle.
a) prevent initiation of hazardous machine motion (or

situation) until the failure is corrected or until the control
system is manually reset; or
b) initiate an immediate stop command and prevent reinitiation of hazardous machine motion (or situation)
until the failure is corrected or until the control system is
manually reset; or
c) prevent re-initiation of hazardous machine motion (or
situation) at the next normal stop command until the
failure is corrected or until the control system is
manually reset.
Other failures cannot be detected until a demand is

made on the safety-related function. An example of
such a safety-related function may be the use of an
electro-optical device protecting a hazardous area
where individuals do not normally enter the area
during a normal machine cycle. When a failure is
detected, the safety-related function should meet the
requirements of this subclause.
In the presence of a failure, the user shall be responsible

to ensure that repetitive manual reset of the system or
device is not used for production operation.
In the presence of a failure, it is recognized that

some control systems or devices can be manually
reset or can be reset by cycling the power to the
system or device off and on.
The intention of a manual reset is to aid in the
diagnosis of a failed component, subassembly,
device or module. A second failure may occur
during the diagnostic or troubleshooting process,
negating the safety-related function(s). Additional
protective measures should be used to protect
individuals during this process.
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B11.202004
Control reliability:
is one of the design strategies that may be

used to meet these requirements;
cannot prevent a repeat cycle in the event of a

major mechanical failure or in the presence of
multiple simultaneous component failures;
is not provided by simple redundancy. There

must be monitoring to assure that redundancy
is maintained.
For further information on safety-related functions, see
Annex C.
8.9
Safety related span of control
E8.9
The safety related span of control shall be determined by the Examples that have an associated span of control are:
physical layout of the integrated manufacturing system, the
emergency stops;
production process itself, and the access necessary for the
enabling devices;
completion of tasks.
resets;
gate interlocks;
The safety related span of control shall be verified by the risk
presence sensing devices.

assessment.
See also, Annex D and ANSI B11.TR3.
Unless clearly distinguishable, the span of control shall be
identified.
Means of identifying span of control may include

placards, color-coding, signage, shapes, layout and
location, etc.
8.10
E8.10
Muting
Muting shall be permitted when:

a) individuals are not exposed to the hazard;
b)
the hazard cannot be accessed without a stop being b) Physical barriers or obstructions can prevent
initiated;
access.
c)
the muting system is designed and installed consistent c) Muting is typically accomplished by interface
with the safety circuit performance requirements from circuits or auxiliary controls. A simple cam-operated
limit switch wired in parallel with the devices output is
the risk assessment;
inadequate, as its failure can remain undetected.
d)
for operator interface application(s), presence in the d) Continual sensing is typically meant for parts
muted safeguarded space is continually sensed.
loading applications where personnel are expected to
enter an area protected by a safeguarding device
which is muted and then exit prior to the next cycle in
the safeguarded space. Muting to allow the entry of a
part requires alternative sensing to detect personnel
intrusion, but is not required to detect deliberate acts
e.g., riding inside a car body.
In the event of a failure of the safety related part of the
muting function, subsequent muting shall be prevented until
the failure is corrected.
8.11
Safety related system reset
8.11.1 When individuals can pass into the

span of control space and place themselves
safeguard(s) and the hazard area:
a) additional safeguarding measures shall
conjunction with the safeguards to
individual from exposure to the hazard; or
safeguarded E8.11.1 See also, ANSI / NFPA 79 for additional

between the information on reset devices.
be used in
prevent the
28
B11.202004
b) the safety system shall require that the device or safety

system be manually reset before hazardous motion can
occur. The sole action of closing a guard shall not
reset the safety system.
b) This situation is not point of operation guarding.

In addition to closing the guard(s), means of
manual reset can include but are not limited to
pushbuttons, slide bolts, trapped key systems,
manually actuated safety switches, or other
means of providing additional intentional
action(s) to reset the safety system.
8.11.2 When used or required by 8.11.1 (b), the reset

device shall be located outside of the safeguarded space
such that the safety system cannot be reset from within the
safeguarded span of control space.
8.11.3 Reset of the safety system shall only be performed
after the safeguarded span of control space is clear of all
individuals.
8.11.4 The entire safeguarded span of control area shall E8.11.4 A reset device should be located near the
be visible from the single reset device location, or a method point of access. Possible methods of detection of
for detecting personnel in the non-observable location(s) personnel include but are not limited to:
shall be used.
automatic detection by means of protective

devices (e.g., presence-sensing devices);
multiple reset devices;
keyed reset or trapped key systems;
vision system (e.g., video monitoring);
procedural policy / programs (safe work

practices).
If a means or method for detecting personnel is not feasible,
visual or audible warning device(s) shall be used in
accordance with the following requirements:
a) operation of the reset function shall immediately
activate the warning device;
b) the warning device shall be continuously activated until
the predetermined warning period has elapsed;
c) the reset function shall be accomplished at the end of
the warning period;
d) a means of preventing reset or restart shall be provided d) a method of accomplishing this function is through
inside the safeguarded space. Operation of this means use of an easily accessible detented pushbutton inside
shall override all safeguarding device resets and the safeguarded space.
start/restart functions.
8.11.5 When multiple reset devices are used to reset the
safety system, they shall be installed such that:
a) The reset locations are positioned to collectively allow
the entire safeguarded span of control space to be
viewed and all reset devices shall be actuated; or
b) The reset locations are positioned to allow full view of
the safeguarded span of control space, and each
device can reset the safety system.
E8.11.5 This usage or installation may incorporate

elements related to pre-determined time, sequence,
location, or position.
When a specific reset sequence is required, the
control circuitry should force this reset sequence and
the control system should have the ability to prompt
for it.
8.11.6 The performance level of the safety reset function

shall be consistent with the risk assessment for single or
multiple reset devices.
8.11.7 Reset of the safety system shall not, in or of itself:
a) restart the machinery or equipment;
b) cause a hazardous situation.
29
B11.202004
Setup, operation and maintenance
9.1
General
E9.1
This clause describes the user requirements for the set-up,

operation and maintenance of the system and its associated
equipment, including training and personal protective
equipment.
During set-up, maintenance, and repair operations,
hazardous situations within the hazard area(s), shall be
under local control.
The user shall establish a lockout/tagout program in See also, 29 CFR 1910.147 and 1910.333.
accordance with ANSI / ASSE Z244.1.
When the system or its associated equipment is modified,
the user shall ensure that set-up, operation and maintenance
procedures are updated and personnel are trained in the
revised procedures.
9.2
Setup
E9.2
The user shall establish and document system setup The objective of this requirement is to ensure proper
procedures in accordance with the supplier's (s') and safe set-up and operation of the system.
recommendations.
See 6.20 for ergonomic considerations and 6.22 for
component lifting considerations.
9.3
Operation
The initiation of normal production operation of the system

shall only be allowed when the following conditions are
satisfied:
a) Operating personnel have been properly trained on the
use of the system;
b) The associated safeguarding is in place and
functioning;
c) No individuals are present within the hazard area(s),
and;
d) Proper safe work procedures are followed.
9.4
Maintenance
E9.4
The user shall establish and follow maintenance procedures The objective of this requirement is for continued safe
for the system utilizing the suppliers instructions and operation of the system.
recommendations.
The procedures shall include a confirmation of the safe Examples of maintaining equipment in a safe manner
operation of the safety equipment after repair, replacement may include, but are not limited to:
or adjustment.
following all recommended safety practices and

procedures listed in this standard that apply to
When it is necessary to disable safeguarding so as to be
their work;
able to perform maintenance, the user shall provide alternate
notifying their supervisor when they observe an

means of safeguarding. The system shall not be returned to
service until the original safeguarding is re-established.
when maintenance personnel install or adjust

safety equipment, devices, guards, or shields,
they should do so as set forth by the user.
9.5
Personal protective equipment
The user shall determine what personal protective

equipment is needed when operating / maintaining systems.
The user shall enforce the proper use of this equipment.
30
B11.202004
9.6
Training
E9.6
The user shall ensure the initial training and the continued
competence of individuals responsible for the supervision,
set-up, operation, maintenance and inspection of the
integrated manufacturing system on safety issues related to
assigned tasks.
9.6.1
Training requirements
Aspects of the training program shall include:
a) Information on the protective measures used;
NOTE This training is best presented when integrated with

operational training.
E9.6.1
b) Task/hazard combinations associated with the system;

c) System set-up;
d) System operation;
e) System maintenance;
f)
g)
h)
i)
j)
k)
The
user
should
refer
to
the suppliers
recommendations when establishing a training
program.
appropriate elements of this standard;

the supplier safety recommendations;
procedures that contain steps related to safety actions;
lockout and tagout procedures;
emergency procedures;
general work place safety procedures.
9.6.2
Retraining
Retraining shall be provided to assure continued safe
operation.
a) Topics include but are not limited to:

types of safeguarding devices;
capabilities/options of safeguarding devices;
description of devices selected for a specific
application;
function of the selected devices;
functional test of the device;
limitations of the selected device.
b) See ANSI B11.TR3 and Annex B of this document;
c) Topics include but are not limited to:
procedures for all set-ups;
procedures for changing, replacing and adjusting
fixtures/tooling;
transport, and storage of fixtures/tooling;
hazards associated with alternate means of
safeguarding.
d) Topics include but are not limited to:
machine tasks;
hazards related to each task;
response to abnormal/unexpected events;
recovery of operation;
use of auxiliary equipment.
e) Topics include but are not limited to:
applicable system training;
emergency operations;
hazards involving:
preventive maintenance/calibrations;
troubleshooting;
repair;
operational checks;
malfunctioning safety devices;
malfunctioning communication systems;
process variables;
process materials;
procedures on live systems versus systems

disabled by lockout, e.g., alternate means of
safeguarding;
auxiliary equipment.
f) Other standards may apply;
j) Including span of control for e-stop devices.

E9.6.2
Reasons for retraining may include, but are not
limited to:
a) system
changes
(i.e.,
reconfiguring
or
reprogramming the system);
b) after an incident;
c) refreshment / enhancement.
31
American National Standard
B11.202004
Annex A - Illustrative examples of integrated manufacturing systems

(Informative)
Physical
Environment
& Power
Sources
Supervisory
Control
Awareness
Devices
Op. Station
Local Area Network/

Data Link
Safeguards &
Interlocks
Stop
Devices
Safeguarded Space
Hazard
Area
Hazard
Area
Hazard
Area
Hazard
Area
Raw Material
& Tooling
Scrap &
Expendables
Finished
Goods
Figure A.1 Simple block diagram of an example integrated manufacturing system
32
B11.202004
Figure A.2 An example of an integrated manufacturing system using a robot as the material
handling system, and showing perimeter barrier, fixed barrier guard with interlocked gates,
presence sensing devices, awareness devices, and system emergency stop devices
33
B11.202004
Figure A.3 Integrated manufacturing system comprised of several zones
Figure A.4 Areas to be considered for safeguarding
34
B11.202004
Annex B - Examples of hazards, tasks, and task/hazard pair lists

generated by an integrated manufacturing system risk assessment
(Informative)
Annex B is intended only as a representative example, and does not show a complete risk assessment. Tables B.1
and B.2 are provided as real example lists of hazards and tasks that were the output of a task-based risk assessment
performed on an Integrated Manufacturing System in an automotive metal fabrication plant. The IMS contained
several machine tool stations within a zone, linked together by a material handling system, and interconnected with
and coordinated by a programmable control system. Table B.3 shows a sampling of the task/hazard pairs generated
by this risk assessment.
For this example application:
Specific hazards were identified and are generally listed as shown in Table B.1, and
Specific tasks were identified, as shown in Table B.2, and
The risk assessment process utilized on this application generated more than 400 specific Task/Hazard pairs
which needed to be addressed in some manner, of which a representative listing is shown in Table B.3.
For the purposes of this example, it is important to understand what some of these terms mean:
The term hazard refers to a specific movement, a state of a machine component, or a state of the environment
in the IMS area that could be a potential source of harm to an individual.
Terms such as conveyor motion, clamp motion, hot metal, obstructed egress, are descriptions of specific
hazards.
The term task refers to an identified work item that any individual must perform in the area of a hazard(s)
during the operation, maintenance or clean-up of the IMS.
Terms such as operator loads parts, replace clamp, un-jam nuts at loader, retrieve jammed parts, etc., are
examples of specific tasks.
The term hazardous situation refers to a condition that exists when a hazard is matched with a task that an
individual must perform near or upon that hazard, creating a circumstance in which an individual is exposed to
the hazard.
Terms such as crushing, stabbing, hearing loss, inhalation, etc., are NOT hazards. They are the injury
result descriptions of an individual being exposed and injured during a hazardous situation(s).
For a more comprehensive list of hazards and/or hazardous situations, refer to ANSI B11.TR3.
35
B11.202004
Table B.1 Example Hazard List

No.
1.0
Hazards
Process Motion Hazards
1.1
Robot Motion
1.2
End Effector Tooling Motion
1.3
Conveyor Motion
1.4
Fixture/Clamps Motion
1.5
Indexer Motion
1.6
Tipdown Motion
1.7
Turntable Motion
1.8
2.0
Telescoping Tray Motion

Ergonomic Hazard
3.0
Falling Parts Hazard
4.0
Falls Hazard
4.1
Less than 6 feet
4.2
5.0
Greater than 6 feet

Gravity Hazard
6.0
Thermal Hazard
6.1
7.0
7.1
8.0
Hot metal
Electrical Hazard
Live high voltage
Live Stored Energy Hazard
8.1
Mechanical
8.2
Pneumatic
8.3
Water
9.0
Ingress/Egress Hazard
9.1
Low head clearance
9.2
Obstructed Egress
9.3
Slips & Trips
10.0
Sharp Metal Hazard
11.0
Noise Hazard
12.0
Weld Sparks Hazard
13.0
Weld Fumes Hazard
14.0
Mobile Equipment Traffic Hazard
36
B11.202004
Table B.2 Example Task List

Major Equipment
Sta 10-20
Sta 10-20
Sta 10-20
Cell
Cell
Cell
Sta 10-40
Cell
Cell
Cell
Cell
Cell
Cell
Cell
Cell
Cell
Unload Conveyor
Unload Conveyor
Cell
Cell
Cell - Weld Equip
Cell
All Robots
All Robots
All Robots
All Robots
Sta 60D Tipdown
Sta 20 Turntable
Sta 30 Stud feeder
Sta 30 Stud feeder
Sta 30 Stud Hopper
Sta 30 Stud Hopper
Rack Indexer
Controls
Controls
Controls
Sta 50 Date Stamp
Sta 50 Date Stamp
Sta 60 Unload
Tip Dresser
Tip Dresser
Sta 60 Unload
Sta 60D Telescoping Tray
Cell or station
Task Description
Operator loads parts and initiates cycle
Adjust/replace light screen robot side
Adjust/replace light screen operator side
Adjust/replace locators/Pins
Adjust/replace pneumatic components (flow controls-hoses-fittings-cylindicators)
Adjust/Replace electrical components (cords-cables-p/p)
Replace Clamp
Replace transformer
Replace valve
Replace secondary weld cables
Replace weld caps
Replace weld gun
Replace/repair water components (hoses, fitting, etc.)
Troubleshoot tooling
Retrieve Jammed Parts
Retrieve Scrap parts
Service Conveyor - major (Motor, chain, belt, etc)
Un-jam conveyor
Troubleshoot controls - inside cell (EC panels, device net)
Service Utility stand - Air/Water
Weld verification
Housekeeping - inside cell
Service robot & end effector - Major (motor, arm, E/E, robot, etc)
Service robot & end effector - Minor (clamp, prox.sw., hose, fittings, etc.)
Teach robot - inside cell
Troubleshoot robot
Service Tipdown - Major
Service Turntable - Major
Service Nut/Stud loader
Un-jam Nut/studs at loader
Service Hopper
Load Hopper
Service Indexer - Major
Troubleshoot controls - outside cell (panels, device net)
Add/Replace cables in tray on fence
Add/Replace cables in tray on floor
Replace Stamp
Replace Cylinder
Operator unloads part & loads rack
Service Tip Dresser - Major
Service Tip Dresser - Minor
Tag & Close Rack
Repair telescoping tray
Individuals in vicinity (e.g., observer, visitor, stock delivery, etc.)
37
B11.202004
Table B.3 Example Task/Hazard Pair Listing

Major Equipment
Sta 10-20
Sta 10-20
Sta 10-20
Cell
Cell
Cell
Cell
Cell
Cell
Sta 10-40
Sta 10-40
Sta 10-40
Cell
Cell
Cell
Cell
Cell
Cell
Unload Conveyor
Unload Conveyor
Unload Conveyor
Cell
Cell
Cell
All Robots
All Robots
All Robots
Sta 60D Tipdown
Sta 60D Tipdown
Sta 60D Tipdown
Sta 20 Turntable
Sta 20 Turntable
Sta 20 Turntable
Sta 30 Stud feeder
Sta 30 Stud feeder
Sta 30 Stud feeder
Sta 30 Stud Hopper
Sta 30 Stud Hopper
Sta 30 Stud Hopper
Sta 60 Unload
Sta 60 Unload
Sta 60 Unload
Task Description
Operator loads parts & initiates cycle
Adjust/replace light screen robot side
Operator loads parts & initiates cycle
Adjust/replace locators/pins
Adjust/replace pneumatic component
Adjust/replace electrical component
Replace clamp
Replace clamp
Replace clamp
Replace transformer
Replace transformer
Replace valve
Replace secondary weld cables
Replace water components
Retrieve jammed parts
Service conveyor-major motor
Un-jam conveyor
Un-jam conveyor
Troubleshoot controls inside cell
Weld verification
Housekeeping inside cell
Service robot & end effector-major
Service robot & end effector-minor
Teach robot inside cell
Service tipdown - major
Service tipdown major
Service tipdown major
Service turntable major
Service turntable major
Service turntable - major
Service stud loader
Service stud loader
Un-jam studs at loader
Service hopper
Service hopper
Load hopper
Operator unloads part
Operator unloads part
Operator loads rack
Hazard
Process Motion: Robots
Process Motion: Clamps
Sharp Metal
Process Motion: Indexer
Process Motion: Tipdown
Process Motion: End Effector
Low Head Clearance
Pinch Points
Slips & Trips
Process Motion: Robot
Obstructed Egress
Live Energy - Pneumatic
Process Motion: Conveyor
Live High Voltage
Process Motion: Clamps
Process Motion: Tipdown
Live Water
Sharp Metal
Live High Voltage
Process Motion: Conveyor
Pinch Point
Process Motion: Turntable
Hot Metal
Slips & Trips
Low Head Clearance
Process Motion: Robot
Gravity
Pinch Point
Process Motion: Turntable
Ergonomic: Lifting
Live High Voltage
Slips & Trips
Weld Fumes
Sharp Metal
Live Energy: Pneumatic
Noise
Weld Sparks
Process Motion: Indexer
Pinch Points
Sharp Metal
38
B11.202004
Annex C Performance of the safety-related function(s)

(Informative)
The purpose of the requirements of this standard is to prevent exposure to hazardous motion (or situations). The level of
performance of the safety-related function(s) depends on the level of risk associated with the hazard. See clause 5. There are
various design strategies that may be used to ensure that failures of components, modules, devices or systems meet the level
of performance required above. Some design strategies may allow an accumulation of single failures and yet still stop (or
prevent the re-initiation of) hazardous motion (or situations) when the next critical failure would cause loss of the safety-related
function. Other strategies include self-diagnosis to determine and respond to failures. Still other strategies use tried and
proven components and design principles to reduce the probability of a failure to a tolerable risk. Control reliability is a design
strategy, method or feature that separates the safety-related functions of a system into components, modules, devices or
systems that can be monitored or checked by other components, modules, devices or systems. It is axiomatic that protection
from the loss of safety-related functions due to multiple, simultaneous independent failures of components, sometimes referred
to as fail-safe, is not practically achievable. Catastrophic failure of the machine actuator (electrical, mechanical or fluidic),
may result in the loss of the safety-related function.
The use of redundant components, modules, devices or systems (with or without monitoring or checking) is frequently used in
process control systems where the goal is to maintain the process in the event of a failure. Aircraft systems, chemical
processing plants and electrical power transmission systems are examples of applications where the process must continue in
the presence of a failure. Control reliability is not provided by simple redundancy. There must be monitoring to assure that
redundancy is maintained. Control reliability uses monitoring and checking to determine that a discernable component,
module, device or system has failed and that the hazardous motion (or situation) is stopped, or prevented from starting or
restarting. Control reliability ensures that a failure of the control system or device will not result in the loss of the safety-related
function(s).
NOTE - Because some failures cannot be detected until the completion of a cycle or a portion of the cycle, loss of safetyrelated functions may occur for a portion of the machine cycle.
Control reliability of electrical, electronic, pneumatic, or hydraulic systems or devices frequently consists of monitored, multiple
and independent parallel or series components, modules, devices or systems. Control reliability of machine control systems or
devices can be achieved by the use of, but not limited to, one or both of the following:
The use of two or more dissimilar components, modules, devices or systems, with the proper operation of each being
verified (monitored) by the other(s) to ensure the performance of the safety function(s).
The use of two or more identical components, modules, devices or systems, with the proper operation of each being
verified (monitored) by the other(s) to ensure the performance of the safety function(s).
These methods require that the protective device, its interface to the control system (or directly to the actuator control) and
actuator control meet the above requirements.
Another control reliability strategy may be used when the machine motion is stopped and reinitiated at least once per cycle.
This strategy requires that the control system and the actuator control utilize the design methods above. The protective device
and its interface may or may not be control reliable. To ensure that these elements cannot cause a loss of the safety-related
function(s), the control system must be designed to require that the device and its interface is exercised automatically or by the
operator (e.g., releasing hand controls or interrupting an electro-optical device) before a subsequent machine cycle may be
initiated.
NOTE The requirements of control reliability are not comparable to the requirements of ISO 13849-1, and exceed the
requirements of category 2.
The achievement of control reliability is dependent upon the selection and integration of components, modules, devices and
systems that have been specifically designed and intended for use in safety-related functions. A disciplined design process,
including design guidelines, peer review and other elements, is important for achieving completeness and accuracy of the
design, and should be implemented to ensure that control reliability is achieved.
39
B11.202004
Annex D - Safety related span of control examples within an IMS

(Informative)
The figures below show examples of how the safety related span of control of an IMS safety system may be implemented.
Reset
Acc es s #1
Open
E-Stop
Reset
E-Stop
A cces s #2
Closed
Reset
E-Stop
Acces s #3
Closed

Entire IMS
Safeguarded Space
M ater ial
M achine
H azard
Zone
M ater ial
M achine
H azard
Zone
M achine
M ater ial
M achine
H azard
Zone
M achine
M ater ial
M achine
P er im et er
Gu arding
Entire IMS shut down due to Access #1
Safet y S ystem (s)
Figure D.1
Figure D.1 shows an IMS comprised of one safety system controlling a system of three zones, six machines and the material handling system (i.e., the hazards).
The span of control of each access gate is the entire system. Opening any access gate initiates a stop command, and prevents restarting of hazardous motion.
Additional protective measures may be required to address any remaining hazards.
40
B11.202004
Access #1
Open Reset E-Stop
Reset E-Stop

Zone 2 of IMS
Safeguarded Space
Zone 1 of IMS
Safeguarded Space
Material
Hazard
Zone
Machine
Machine
Access #2
Closed
Material
Hazard
Zone
Machine
Material
Machine
Material
Machine
Hazard
Zone
Material
Machine
Perimeter
Guarding
Zone 1 of IMS shut down due to Access #1
Safety System(s)
Figure D.2
Figure D.2 shows an IMS comprised of a safety system controlling two zones. The span of control of each access gate is the zone defined by the perimeter
guarding. Opening an access gate initiates a stop command, and prevents restarting of hazardous motion associated with the access gate. Additional protective
measures may be required to address any remaining hazards.
41
B11.202004
Access #1
Open
Reset E-Stop
Reset E-Stop

Zone 1 of IMS
Safeguarded Space
Material
Machine
Hazard
Zone
Material
Machine
Zone 1 of IMS shut down

due to Access #1
Zone 2 of IMS
Safeguarded Space
Material
Hazard
Zone
Machine
Material
Machine
Access #2
Closed
Reset E-Stop
Access #3
Closed
Zone 3 of IMS
Safeguarded Space
Material
Machine
Hazard
Zone
Material
Machine
Perimeter
Guarding
Zone 2 of IMS shut down

due to Access #4
Access #4
Open
Safety System(s)
Figure D.3
Figure D.3 shows an IMS comprised of a safety system controlling three zones. The span of control of each access gate is the zone defined by the perimeter
guarding. Opening an access gate initiates a stop command, and prevents restarting of hazardous motion associated with the access gate. Opening an access
gate between zones initiates a stop command, and prevents restarting of hazardous motion associated with the adjacent zones. Additional protective measures
may be required to address any remaining hazards.
42
B11.202004
Annex E - Zone Determination

(Informative)
In order to determine the zone(s), a layout analysis should be carried out to have an overall understanding of the
impact of the foreseen tasks on the functional performance of the IMS.
A zone may include:
Space within or around the IMS which is used by personnel to go towards a specific location, an operating
position or a servicing point;
Space within or around the IMS in which personnel perform standard production operations or other tasks.
The following aspects should be identified during the layout analysis:
The portions of the IMS that can be stopped during the time needed to perform the intervention without
preventing the rest of the IMS from performing its function;
The critical portions of the IMS that prevent the rest of the IMS from performing its function when those critical
portions are stopped. They are critical because each intervention will have a direct impact on the production
level of the IMS;
The servicing points and the operating points;
The routes through the IMS to access the servicing points or operating points.
Review the task/hazard pairs from the risk assessment to:
Identify access and service areas and protective measures for each individual task/hazard pair;
Combining common protective measures of the individual task/hazard pairs will determine task zones and
span of control.
After identifying the above, the IMS can be divided into appropriate zones:
To accommodate the task zones;
To allow a portion of the IMS to continue production while tasks are carried out within an individual zone.
Layout is an iterative process which may require one or more of the following:
Modify the layout, the IMS functionality or the IMS limits;
Change or modify some equipment in order to suppress or modify some tasks;
Determine new access means;
Modify the way the tasks are performed.

Design reviews are part of the iterative process described above. When tolerable risk and IMS functionality have
been achieved, layout analysis is complete.
Figures E1 through E6 provide an example methodology for determining zones.
43
B11.202004
Machine 3
conveyor
Machine 1
Robot
Machine 2
Milling machine
IMS
Figure E.1 Create a preliminary layout of the components of the IMS
IMS
Hazard
Figure E.2 Identify the hazard zones
44
Access to
Task 3
B11.202004
Task 3:
Effector changing
Task 1: robot
servicing
Task 2:
cleaning
Access to
Task 2
Access to
Task 1
Figure E.3 Determine the tasks and their requirements and access
Equipment Zone 1
Equipment Zone 2
Figure E.4 Determine the equipment zones taking into account safety and productivity
45
B11.202004
Task Zone 1
Combined Task
Zones 1 and 2
Task Zone 3
Task Zone 2
Figure E.5 Task Zones are determined for each task and combined when similar.
Task: 3
Protective Measure: Light Curtain
Access Type: Partial Body
Span of Control: Robot
Tasks: 1 and 2
Protective Measure: Gate Interlock
Access Type: Full Body
Span of Control: Robot and Machine
Figure E.6 Define the span of control of each protective measure
46

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ANSI B11.

American National Standard for Machine Tools

Safety Requirements for

ANSI-Accredited Standards Developer and Secretariat:

Approved: July 1, 2004

Licensed to J. R. Automation Technologies, Inc./Mary Violante

AMERICAN NATIONAL STANDARDS

AMT The Association For Manufacturing Technology

TASK AND HAZARD IDENTIFICATION .......................................................................................... 11

DESIGN AND CONSTRUCTION ...................................................................................................... 13

SUPPLIER'S RESPONSIBILITY ....................................................................................................... 7

LAYOUT, INSTALLATION, AND VALIDATION............................................................................... 22

SETUP, OPERATION AND MAINTENANCE................................................................................. 30

ANNEX A - ILLUSTRATIVE EXAMPLES OF INTEGRATED MANUFACTURING SYSTEMS........... 32

FOREWORD (This Foreword is not part of the requirements of American National

Natl. Inst. for Occupational Safety & Health

John Etherton, PhD

Chairman (3/01 2/02)

Chairman (3/02 9/02)

Toyota Motor Manufacturing, NA

Toyota Motor Manufacturing, NA

Deere & Company

Levitt & Associates

Stuart C. Irby Company

Bruce Main, PE, CSP

design safety engineering

Ford Motor Company

Scientific Technologies Inc.

Roberta Nelson Shea

STI Machine Services, Inc.

General Motors Corporation

Toyota Motor Manufacturing, NA

This ANSI B11.20 2004 standard is divided into parts

Licensed to J. R. Automation Technologies, Inc./Mary Violante

Overall workplace safety

Task and hazard

Design and construction (6)

Layout, installation, testing

Set-up, operation and

AMERICAN NATIONAL STANDARD

American National Standard for Machine Tools

Safety Requirements for Integrated Manufacturing

This American National Standard specifies the safety

The terms integrated manufacturing system, and

An integrated manufacturing system:

Integrated manufacturing systems may be comprised

An integrated manufacturing system shall be designed and

This standard does not cover:

a) Where machines and equipment of an

b) transfer machines or transfer lines;

b) See ANSI B11.24.

c) continuous flow processes.

c) Examples of continuous flow processes include

pulp and paper;

AMERICAN NATIONAL STANDARD

AMERICAN NATIONAL STANDARD

For the purposes of this standard, the following definitions

See also, ANSI Z535.1, Z535.3 and Z535.4.

barrier: A physical boundary to a hazard.

AMERICAN NATIONAL STANDARD

See also, safety related function.

E3.17 Examples of fixtures are universal tables,

E3.19 Harm may be a result of direct interaction