2008 Volume 1 Issue 3 Pages 219-229
Integrated Manufacturing System (IMS) is an automated system that allows multiple machines to be controlled in harmony with each other. Even though we refer to it as an automated system, it is necessary for operators to intervene in IMS for operations such as shift-change, confirmation of operation, trouble shooting, maintenance/ inspection, repair and cleaning. When these operations are carried out, an accident resulting in injury or death might occur as a result of collisions between operators and machines if an inharmonious relationship between operators and machines exists. Thus, IMS needs to be implemented in conjunction with risk reduction methods so that any failure in this relationship can be predicted and also to avoid possible injuries. The objective of this study was to devise processes that would reduce IMS-related risks, Processes to reduce risk need to be considered in relation to the following hazardous conditions. (1) Operators encroach into manufacturing lines a previous machine-related issue. (2) Operators perform incorrect re-start procedures. (3) Multiple operators intrude into a manufacturing line at the same time. (4) Operators' movement across areas of the manufacturing line that are divided up into multiple zones. However, as many hazardous conditions exist, it is difficult to define all of the safety requirements and to implement safety measures. In order to define safety requirements more easily at the system design stage, this paper proposes a method that requires design engineers only fill in four forms, which will be described later. This study also formulated systematic processes to reduce risk in IMS by applying new concepts such as classification of risk management, Classification of the various protection methods and operations carried out under hazardous conditions. Applying the proposed procedure, a building system made up of modules (for which the safety has been demonstrated in advance) will make it easier to verify (certify) safety of the system and will improve productivity when the safety system is implemented. These results will be utilized in a reconsideration of the ISO11161 standard in relation to Integrated Manufacturing Systems (IMS).
