Practical Benefit of Risk Assessment:

Zone Determination by Layout Analysis

Chris Soranno
Certified Safety Application Specialist
FS Eng Machinery, TÜV Rheinland
SICK, Inc.
What is a ‘Zone’?

• A zone may include space within or around

the system:
– which is used by personnel to access a specific
location, an operating position or a servicing point;
– in which personnel perform standard production
operations or other tasks.
Why Create Zones?
• Automation systems should be designed to
facilitate safe manual interventions

Set-Up Operation Troubleshooting Maintenance

• For some manual interventions, it may be

impractical to stop the whole system
… in which case the system should be
segregated into zone(s) where personnel
can perform their tasks safely
Where is Guidance Available?
• ANSI/RIA R15.06-2012, Part 2
5.9 Integrated manufacturing system (IMS) interface
– 5.9.1 General
– 5.9.2 Emergency stop
– 5.9.3 Safety-related parts of the IMS
– 5.9.4 Local control
– 5.9.5 Enabling device
– 5.9.6 Mode selection
– 5.9.7 Task zone implementation
Where is Guidance Available?
• ISO 11161:2007
– Safety of machinery — Integrated
manufacturing systems — Basic
requirements

• ANSI B11.20-2004 (R2015)

– Safety Requirements for
Integrated Manufacturing
Systems
 Interrelationship of Standards
• This figure describes the relationship of the scope of machinery standards used in a robot system
• The robot alone is covered by Part 1, the system and cell is covered by Part 2
• A robot cell may include other machines subject to their own C level standards, and the robot
system can be part of an integrated manufacturing system covered by ISO 11161 which in turn can
also make reference to other relevant B and C level standards
• Part 2 adds additional information in line with ISO 12100 and ISO 11161
ISO 10218-1 ANSI/RIA R15.06
(Part 1)
Robot
ISO 10218-2 ANSI/RIA R15.06
Robot Other machine (Part 2)
system/cell (C-type) standard
ISO 11161 Integrated Manufacturing System ANSI B11.20
(IMS)
ISO 12100 RIA R15.306 &
RISK ASSESSMENT ANSI B11.0

Source: ANSI/RIA R15.06, Part 2, Figure 1

 Interrelationship of Standards

Image Source: ANSI/RIA R15.06, Part 2, Annex B

Integrated Manufacturing Systems
An integrated manufacturing system (IMS):
a) incorporates two or more industrial machines
which:
1) can operate independent of each other, and
2) are intended for the purpose of manufacturing,
treatment, movement or packaging of discrete
parts or assemblies;
b) is linked by a material handling system; and
c) is interconnected by a control system(s) for
coordinated operation
Span of Control & Layout Analysis
Additional guidance in future ANSI B11
type-C standards:
– The span of control of safety-related control devices
shall be determined by a layout analysis, which
includes:
• Specification of the limits
• Task/hazard pairs as identified from a risk assessment
• Task zone identification
• Selecting risk reduction measures
• Control zone identification
 Risk Assessment Process

Image Source: ANSI B11.0-2015, Figure 6

Used with permission
Referenced by RIA TR R15.306-2016, Clause 6
Layout Analysis Process
Comparison of Processes
Combination of Processes

Risk Assessment Process Layout Analysis Process

EXAMPLE: Palletizing Cell
 Identification of Tasks
A: Load/Unload Pallets E2
B A B: Cleaning E1
C: Teaching Robot E1
D: Jam Clearing E2
E: Conveyor Maintenance E1

1) task: specific activity

performed by one or
more persons on, or in
the vicinity of, the
machine during its life
cycle

2) task: Any specific

activity that is done with,
on or around the
machine during its
lifecycle.
D E D C B A
Definition Sources: 1) ISO 12100-1:2010
2) ANSI B11.0-2015
 Identification of Hazard Sources
1: Robot / End Effector
2: Conveyor Lifts
3: Conveyors

hazard: A potential
source of harm

2 3 2 1
Definition Source:
ISO 12100-1:2015, ANSI B11.0-2015
 Identification of Hazard Types
1: Robot / End Effector
2: Conveyor Lifts S3
3: Conveyors S1
2: Conveyor Lifts
S3
S1
S2
3: Conveyors
S1

2 3 2 1
 Identification of Hazard Types
1a: Crushing
1b: Dropped parts

2a: Shearing
2b: Pinching
2c: Entanglement

3a: In-running nip points

2 3 2 1
 Identification of Task Zones
I: Load/Unload & Cleaning
I II: Teaching Robot
III: Jam Clearing
IV: Maintenance

task zone: Any

predetermined space within
or around a machine in
which a person can perform
work
III IV III II I
Definition Source:
ISO 11161:2007, ANSI B11.20 – DRAFT #5
 Identify Task / Hazard Pairs
HAZARDS ROBOT CONVEYOR LIFTS CONV.
1a 1b 2a 2b 2c 3a
Dropped In-Running
TASKS Crushing
Parts
Shearing Pinching Entang.
Nips

A L/UL 1 2 - - - - E2

B Cleaning 3 4 - - - - E1

C Teaching 5 6 - - - - E1

D Clearing 7 8 9 10 11 12 E2

E Maint. 13 14 15 16 17 18 E1

S3 S1 S3 S1 S2 S1
 Risk Estimation
Haz- Sever- Exp- Avoid- Risk PLr /
ID Task
ard ity osure ance Level Cat
1 A 1a S3 E2 A1 HIGH d/3
2 A 1b S1 E2 A2 HIGH d/3
3 B 1a S3 E1 A1 HIGH d/3
4 B 1b S1 E1 A2 MED d/2
5 C 1a S3 E1 A1 HIGH d/3
6 C 1b S1 E1 A2 MED d/2
7 D 1a S3 E2 A1 HIGH d/3
8 D 1b S1 E2 A2 HIGH d/3
9 D 2a S3 E2 A3 VERY e/4
10 D 2b S1 E2 A3 LOW c/2
11 D 2c S2 E2 A3 HIGH d/3
12 D 3a S1 E2 A1 LOW c/2
13 E 1a S3 E1 A1 HIGH d/3
14 E 1b S1 E1 A2 MED d/2
15 E 2a S3 E1 A3 HIGH d/3
16 E 2b S1 E1 A3 LOW c/2
17 E 2c S2 E1 A3 MED d/2
18 E 3a S1 E1 A1 NEG b/-

Image Source: RIA TR R15.306-2016

Table 2 & Table 5
Control Zones for Coexistence
Control Zone C

Control ZoneControl
A Zone B
 Apply Protective Measures

Safe!
But not very efficient…
 Risk Reduction Measures
R
R R

R R R
 Safety-Related Span of Control
R
Control Zone C
R R

Control ZoneControl
A Zone B
R R R
EXAMPLE: Palletizing Cell
Interaction Matrix w/Span of Control
SAFETY-RELATED COMPONENTS HIGHEST LEVEL OF SAFETY PERFORMANCE
FUNCTION DEVICE LOCATION ROBOT CONVEYOR LIFTS CONVEYORS
Light Curtain Conveyor Entrance d/3 e/4 c/2
Door Interlocks Lift Doors d/3 e/4 c/2
PROTECTIVE

Door Interlocks L/UL Doors d/3 e/4 c/2

STOP

Door Interlock Maintenance Door d/3 e/4 c/2

Light Curtains L/UL Stations d/3 - -
Area Scanners L/UL Stations d/3 - -
Position Switches Robot Primary Axes d/3 - -
E-stop Pushbutton Conveyor Entrance c/2 c/2 c/2
EMERGENCY

E-stop Pushbuttons Lift Doors c/2 c/2 c/2

STOP

E-stop Pushbuttons L/UL Doors c/2 c/2 c/2

E-stop Pushbutton Maintenance Door c/2 c/2 c/2
E-stop Cable Pull Cell Interior c/2 c/2 c/2
Reset Pushbutton Conveyor Entrance d/3 e/4 c/2
Reset Pushbuttons Lift Doors d/3 e/4 c/2
RESET

Reset Pushbuttons L/UL Stations d/3 e/4 c/2

Reset Pushbutton Maintenance Door d/3 e/4 c/2
Muting Sensors Conveyor Entrance d/3 e/4 c/2
AUXILIARY

Mute Override Conveyor Entrance d/3 e/4 c/2

Awareness Lights L/UL Stations d/3 - -
Review
1. The risk assessment process: Process
– is used to reduce risks
– is also used to more logically isolate /
segregate various zones within complex Risk Productivity
automation systems

2. Involvement of design engineers (systems,

controls, etc.) in the risk assessment
process is important in order to achieve
maximum safety and productivity

3. Other industrial safety standards can and

should be used for additional guidance to
maximize the results of a risk assessment
Contact Information

Chris Soranno
Certified Safety Application Specialist
FS Eng Machinery, TÜV Rheinland
Minneapolis, Minnesota USA

Telephone: +1 (216) 513-8470

chris.soranno@sick.com