In the process industry, regulatory compliance is constantly changing due to process fragmentation and business growth. Process industries around the world are surrounded by issues such as technology gaps, regulatory compliance, and most importantly, increased workplace safety costs. Compliance issues will be directly related to increased incidence of accidents and injuries in the workplace, ineffective risk analysis, and inefficient predictions.
Traditional methods used by the process industry to ensure safety management and potential hazard identification, such as Hazard and Operability Analysis (HAZOP), have become an important tool for achieving compliance. By addressing the engineering and design expertise of the industry in manufacturing, the associated challenges can be addressed. A new process security management model attempts to check the composition of the overall problem by solving each problem. At the same time, it is necessary to use digital technology and build a greater trust with employees through an improved work environment.
In the factory floor, there are some safety concerns related to manual installation, operation or machine maintenance, and electrical safety. In order to minimize the number of worker injuries and accidents in these interactions and to design workflows and terms, the first step is to conduct a detailed inspection and analysis of existing workflows, assess the level of risk, and identify What can be worrying. The insight gained through this process helps to create specific and targeted interventions to bridge the gap.
The first and most important phase of machine risk assessment begins with the development of a virtual solution that is progressively refined through an iterative process. In the next phase, the selected design is prototyped and mounted on a three-dimensional replica of the machine for testing and subsequent fine adjustments. The next step is to follow the processing, assembly and installation of the safety protection system. Each step is regulated according to safety guidelines.
In terms of electrical safety, a similar process must be followed to begin with a comprehensive inspection, identify risk areas, and develop detailed plans for managing or mitigating risks. Relevant assessments include load flow studies, short circuit studies, tuning studies, grounding grid studies, and more. Based on these findings, settings on the device can be modified to help ensure device protection, reduce arc flash, and reduce system outages. Another form of presentation is the optimization of the order of operation of the protection device. Certified machine safety experts and electrical safety experts should be familiar with industry standards and regulations related to machine safety.
Digitization and predictive analysis According to information provided by the ILO, there are 600 work-related accidents per minute worldwide. Worried about the increasing incidence of such incidents, even those with physical security measures now digitize the operation of the factory floor to accommodate and ensure safety.
The latest industrial trends are moving towards Industry 4.0. Increasing the level of intelligence by increasing the connectivity between machines in the factory floor benefits the entire supply chain. Real-time monitoring and predictive alerts help mitigate security risks and increase productivity.
Automated alarms, statistical analysis, predictions, and inferences are provided through advanced insights at each level through advanced data analysis, and security incidents are avoided. Predictive analytics can deliver tangible benefits to businesses, such as a large manufacturing company that reduces security incidents by 75%. Workplace safety and equipment monitoring are parallel. Some industries use digital vision technology to effectively monitor remote areas, and by other means it is difficult to monitor these areas.
In this way, the Industrial Internet of Things (IIoT) has also found its own use in predictive equipment maintenance to avoid accidents and provide better products and services. This development becomes especially valuable for industries where workers are often exposed to hazardous work environments. Benefits include improved health and safety, yield, efficiency, product quality, production value, and market share, offsetting the investment necessary to initially deploy IIoT-based security management.
Wearable products have fundamentally changed the concept of personal protective equipment (PPE) and are no longer limited to security originals or gloves. With existing sensors added to the manufacturing infrastructure, information can be collected, transmitted, and analyzed to predict and avoid risks. Cloud connectivity increases the speed and efficiency of sharing data with workers.
The RF chips on the worker's helmet and the sensors on the device monitor and help avoid safety issues and accidents, which in turn can translate into long-term cost savings and enhanced compliance. Other new technologies such as augmented reality and virtual reality enable more efficient security detection. By simulating expected conditions, diagnosing problems, and assigning them to a safety maintenance team, these technologies equip testers with valuable visualization tools. Forecasts show that digital factories are the future of manufacturing, allowing machines to network and collaborate with another machine for faster work and greater efficiency. At the same time, when digital technology is integrated with machine safety and electrical safety protocols and related hardware and software, it also enhances process security management.
Digital Transformation of the Process Industry Strategic design thinking can take a holistic approach to the complex and pressing issues associated with worker safety. Simplified protocols for handling machine safety and electrical safety help reduce injuries, occupational exposures and casualties. Digital technology enables manufacturers to go beyond basic compliance and actively develop policies that improve worker safety and well-being.
Through smarter technologies, policies, and practices, process industry manufacturers can deepen their trust and increase performance, capacity, and output. The effective integration of smart technologies into the manufacturing process lays the foundation for the process industry to enter the digital future, while at the same time being more confident in its ability to integrate more extensive emerging technologies to accommodate more diverse needs and add value.
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