SICE Annual Conference 2007

Sept. 17-20, 2007, Kagawa University, Japan

Trend of International Safety Standards

Kotaro Amanuma
Safety Design Department, Yamatake Corporation
(Tel: 81-466-20-2430, E-mail:Amanuma-kotaro@jp.yamatake.com)

Abstract: Safety standards have been applied to variety of field in society, and will be increasing in number and
categories. Trend of international safety standards and organizational work for the standards are discussed and recent
activities relating to IEC safety international standards of NECA (Nippon Electric Control Equipment Industries
Association) are also reported.
Keywords: Safety standard, EC, IEC, ISO, ETPIS, NECA, Education, Supply chain, Traceability, Ubiquitous

Layer A is for a basic standard domain that is universall

1. Introduction
European Technology Platform Industrial Safety,
ETPS, was established and compiled detailed report as a
strategic research agenda, SRA.
Industrial safety technology is one of the substantial
issues to build up and maintain economic growth and
quality of life of EC.
In response to it, European Commission adopted
strategy of safety technology in presented as 7th frame
work program.
This means that more number of and integrated standard
will be issued, and relevant laws and regulations
enforced to manufacturing industries.
2. Safety for industrial automated systems
Automation has been provided a variety of benefits to
manufacturing industries and consumers by increasing
productivity, comfort and convenience. On the other
hand, manufacturing industries are facing new
challenges due to globalization and increasing demands
for environmental sustainability and human safety, and
due to complexity of machine and facilities led by
integration with electrical control components and
systems. For this reason, the required solutions in
technologies to ensure safety have been more
complicated. Meanwhile, Social demand for safety has
been accelerating international standard organizations,
such as ISO and IEC to standardize safety related
standards. There many standards compiling safety
related requirements as a result. Manufacturing
industries are concerning for considerable confusion and
risk of wasting resources, to meet those standards.
3. International safety standards
Major part of ISO and IEC safety standards has been
developed based on EN standard.
They have 4 main features.
1. Systematically organized
Standards are classified in 3 layers hierarchical
structure. This system is well known as the safety
pyramid.
y applicable principles and basic rules among all standar
ds. Layer B is for a group standard domain including re
quirements for safety and safety devices applicable to w
ide range of machines. Layer C layer is for individual m
achines and devices standard describing detailed safety r
equirements on specific machines and devices. (Fig.1)
2. Performance provision
Safety of machines and devices are assessed by perfor
mance, not by the specifications such as physical feature
materialized through design and manufacture.
3. Risk assessment based evaluation
Safety level evaluation is done by identifying source of
hazard in products and estimating level of risks emerged
from it and how much risk is reduced through effort,
down to tolerable condition.
4. 3 steps method for reducing risk
To reduce risk, 3 steps of effort are required in the
standards. Effort of
Step1. Designing products intrinsically safe
Step2. Implementing safety protection facility
Step3. Informing residual risks and the directions of
handling them users
Applications of safety standard such as IEC61508 has
been enhanced and applied to many aspects of industrial
field furthermore, such as ISO26262 of automobiles. In
those circumstances, movements to conform those
standards issued by plural international standard
organizations, such as IEC and ISO, have started joint
works. IEC ACOS (Advisory Committee on Safety)
keeps discussing consistency of the standards
between IEC and ISO, and among IEC, categorizing
HSF (Horizontal Safety Function), GSF (Group
Safety Function).
IEC/TC44 and CEN/TC114 organized the working
groups to discuss conformity of IEC61508/IEC62061
and ISO-13849-1, to avoid risk of delivering double
standards and contradictory statements in and among
the standards. The revised edition of these standards are
planned to be issued in 2008. In corresponding to
frequent alternation in standards, manufacturing

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PR0001/07/0000-2901 ¥400 © 2007 SICE
industries have to take more comprehensive and 4-1 Period 1 2000-2003
systematic actions to meet them. Main category was the function required to safety
control components.
(1) 3 positions enable switch
ISO/IEC Guide 51
IS (International Standard) was issued based on the
ISO: Machine IEC: Electric proposal from NECA, as IEC60947-5-8, through
Safety of Machines - Basic Principles
Ａ
Basic Standard:
IEC/SC17B/WG3 deliberation in 2006.
General Design Standard (ISO 12100）
Risk Assessment Standard (ISO 14121)
Universally applicable principles
and basic rules among all
(2) Industrial LED indicating lamp
Interlocks (ISO 14119)
standards. IEC/SC17B/WG3 has started discussion as new item
Electric Facility
Guard System
System Safety
(ISO 14120)
(ISO 13849-1)
Ｂ Sensors: General Standard to adopt IEC60947-5-1 based on NECA proposal.
Sensors: Applied Standard
Safety Related Components
Safety Distance
(ISO 13849-2) Group Standard:
(ISO 13852) Including requirements for
Functional Safety (4) Power reed switch
Switches and like
E-stops
Unexpected Start Prevention
(ISO 13850) safety and safety devices
(ISO 14118) applicable to wide range of EMC 2 items were accepted by TC94 as follows.
Transformers
Hands Operation Control Device
Mat Sensors
(ISO 13851) machines.
(ISO 13856) Explosion Protection Devices 2-1 Power reed switch, IEC62246-2 Ed.1: power reed
Stairs Products (ISO 14122)
For details, see the corresponding ISO or IEC Standard.
Ｃ
switches
Individual Machines Standard:
Detailed Safety Requirements on Specific Machines
2-2 IEC PAS 62246-2-1: Heavy-duty reed switches
Examples: Machine Tools，Industry Robots，Pressure-proof Machines，Pilotless Car，Chemical Plants， Part 2-1: Quality assessment specifications
Transportation Machines, etc.
TC/94 has agreed to develop the related standards, IEC
Fig.1 Safety Pyramid 62246-1 Ed.2: Reed switches – Part 1: Generic standard
and to issue until 2010.
(5) Standardization of user’s guideline for safety
network
4. Activities of NECA The TR of the guideline for applying network to the
safety components was accepted TC44.
NECA (Nippon Electric Control Equipment Industries TC44 has set up SG21 under WG7 to issue TR based on
Association) has been developing safety standards of the draft from NECA.
control components and systems, and dissemination of
safety related concept and technology , under the safety 4-2 Period 2 2004-2006
control committee in NECA. Main category was the function required to safety
For dissemination of safety, NECA developed the control system.
education and safety assessor certification system for (1) Safety identification system applied RFID
the engineers, and managers. Feasibility study was done for applied RFID system
NECA published the safety guide book for the industrial for machinery safety. Through research analysis, system
field engineers and worker. Japanese, English, and requirements and specifications are consolidated and
Chinese editions have been published. discussed in IEC TC199 and others.
As a part of standardization activities, NECA has been (2) Feasibility study of standardization for diagnostics
developing the standards of the control products, and and life prediction technology of control products
proposing them to IEC and ISO, as the project Diagnostics and life prediction technology is important
supported by Ministry of Economy, and Trade and for product safety. Possibility of detecting predictive
Industry (METI), Standard/Certification Research and signs from devices was investigated in this theme, based
Development program since 2001. 2 projects of 3 years on the idea that products functional failure is caused
term each have completed. In the projects, causal relation from parts to product. Standardization
In the projects, NECA made 12 proposals, to IEC as thr of the device profile implemented real time condition
ough effort of research and development. As a result, 4 data was one of the goals. The concept of this theme
proposals were accepted by and 2 subjects are under pro was introduced to and recognized by TC65, SC17B, and
cess of proposing in IEC TCs. TC44, and is to be investigated.
Detect

Electronics
Predictive signs
2004~2006
• Safety identification
identification(RFID
(RFID
2000 to 2003 Application)system
Application) system
• Safety Network • Proactive
PreventiveSafety
maintenance Products Normal Symptom Failure
• ESP diagnostics • Functional Safety
Education of Safety
Hardware Evaluation Technology
• LED Display • Functional Safety
• Operation terminal
• Enable Equipment
Evaluation Technology
Subunits Normal Symptom Failure
• Power Reed Switch
• Safety Switch
Mechanical • Safety Relay Parts Normal Symptom Failure
• Safety Plug
• Contact for Safety

SMALL
Software
LARGE Device status
Fig.3 Detecting predictive sign
Fig.2 NECA projects

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(3) Standardization of education system for safety
NECA developed and originated the educational syste
m and established Safety Assessor Accreditation System
established, collaborating with Certification Corporatio
n (JC) in 2004. NECA and JC cooperate for promoting t
he IEC /ISO -based international standards in the Japane
se industry to improve the safety of machine systems an
d production systems in 2004. This system aims for pro
ducing the professional assessors and educating enginee
rs to the industries. The concept of the standardization w
as proposed to IEC/ACOS, and to be discussed in ad-ho
c group organized by ACOS. Standardization of certific
ation system on personnel competence is still controvers
ial in ACOS.
From 2004 to 2006, 836 people took the course and 530
sub assessors, 65 assessors, and 20 lead assessors are
certified by JC.
Taiwan requested NECA to transfer this system.
NECA has started arrangement.
(Fig.4, 5)
Planning
NECA Control Safety Committee
a) Development of the entire
mechanism
Japan Certification Corporation
a) Operation
b) Coordination of related parties
c) Development of vision and
b) Management of assessors
c) Promotion
concept for the future (JIS, etc.)
Management
Cycle
Education
SOSTAP, TUV -RJ
(safety lead assessors)
a) Development of educational
program
b) Organization of workshop
Fig.4 Education system
Safety Lead Assessor
Skill to evaluate safety as a third party
Acquired high-level special knowledge and completed
training courses successfully. Possess the
comprehensive skill to evaluate safety as a third party.
Safety Assessor
Skill to evaluate the adequacy of safety
Acquired the special knowledge and completed
training course successfully. Possess the
comprehensive skill to evaluate the adequacy of
safety
Safety Sub Assessor
Basic knowledge of safety
Acquired the basic knowledge of safety,
which is necessary to evaluate the
adequacy of safety.
Fig.4 Certification
(4) Standardization of the validation method for
IEC61508 certification
IEC61508 and its related standards need to clearly
specify method to evaluate industrial products. Then the
only limited organizations are capable to certify
conformation to the standards now. This circumstance is
bottleneck to dissemination of safety technologies in the
industries, and furthermore society.
Standardization of the provisions of functional safety
software programming was proposed to IEC TC65,
NECA continues effort to implement this subject to
CDV.
4-3 Period 3 2007-
NECA started the project, feasibility study of global
management and control system of the products, from
June 2007.
The one of the major goals of the study is to develop
the technical standard of traceability for device profiling
with ubiquitous ICT (Information and Communication
Technology).
In the market, huge amount of control products are
globally used. Control products are generally used
for long time、and many of them are used for longer
than 10 or 20 years.
To deal with troubles, such as failure, of the products,
Management
finding and identifying them and their locations as
quickly as possible are most important.
Plants and machineries are equipped with variety of
’ list and cost
control products from variety suppliers. Even one
production line has plural types of control product, PLC,
sensors, and others, from plural vendors. Further more,
Products and assembled parts are supplied to users
through complicated supply chain. In this environment,
Assessment
Accreditation tracing these products and monitoring the conditions,
NECA Safety Assessor properties of them are extremely difficult. In the case of
Accreditation Committee
a) Test development reused at deferent places, machines and facilities,
b) Scoring and evaluation
c) Certification for the qualification disposal, tracing and tracking are almost impossible.
of candidates
(Fig. 6)
Parts Suppliers
Agents Control Products
manufacturers
Agentｓ
・Factories Machine
・Plants Manufacturers &
Engineering
Consumer
Market
Fig.6 Supply chain
To secure safety and to meet environmental regulation,
ensuring traceability is essential, however.
For tracing the products and its information, released
from the manufacturer, identifying the exact product
and the location is the first and imperative step.
As a basic infrastructure for establishing traceability,
the concept of the code system for networked
identifier is described below.
The purpose of the feasibility study is to research
and develop the common code system globally used by
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control product manufactures and users.
Code system based on ubiquitous concept for object
identifying system to is described as follows.
The identifier is one unique code, ubiquitous code
(ucode), provided to one object, such as a product, a
part.
Code system consists of object code and relation code.
Structured products, such as assembled products, are
defined by these codes. Each code has no meaning or
property data and is just like a tag. Code has 128bits
space and assigned 48 bits for individual product
identifier. (Fig.7) This code is used for global
management and control, and linked the existing local
code already used.
This code system is easy to implement technically, by
linking this code with local code that most
manufacturers use in ICT systems.
By linking the identifier code to the products device
profiles in networks or computer database, real time
monitoring of status or condition of the products
becomes realized. Properties of the products are
categorized according to type of information. Type of
data Storage media for them is diverse, from printed
code tag, to high performance RFID holding full scale
data. Other information service is provided by
distributed service servers in network. Configuration of
data storage and information service is freely built by
users.
An example of property and information stored in devi
ces profile is described. (Fig. 9)
Standards of device profiles are developed in IEC
TC65E. SC17B WG is in the process of
standardization will issue as IEC61915.

4bits 16bits 4bits 104bits Supply Chain Global

Version TLDC CC DC(variable) IC(variable) Identifier (ucode) Management
Local ID Enterprise Management
CC(4bits) DC+IC(104bits) ・Plant
1000 Reserved Control Device Profile ・Machinery
・Production Control
Class A 1001 DC(8bits) IC(96bits) Control Device Profile ・User Management
IC(80bits) Product Specification
Class B 1010 DC(24bits)
Class C 1011 DC(40bits) IC(64bits)
*Class D 1100 DC(56bits) IC(48bits) Product Condition
Class E 1101 DC(72bits) IC(32bits) ・Condition
DC(88bits) IC(16bits) ・History
Class F 1110
1111 Reserved
Fig.7 ucode structure Facility Information

Facility Profile
Code system has 2 types of code, representing object Process Data
and relation. Structured objects corresponding to
assembled products are represented by the combination
these codes. (Fig.8) Fig. 9 Category of data

Object Conclusion
ucode

This paper mainly introduced activities of NECA and th

e accomplishment of them, relating to safety internation
al standards. Safety standards should be comprehensi
r-ucode r-ucode
ve and easy to understand、however, these are comp
licate.
IEC61508 has following major problems for exampl
ucode ucode
e.
Object Object (1) Hard to understand and apply
(2) Limited numbers of organizations are capable for
accreditation
These are obstacles against dissemination of IEC61508
Assembly conformed products.
IEC61508 and ISO12100, and the standards derived
from them refer to products related matters. Almost no
standards defined rules or technologies of traceability fo
r safety are found. As mentioned above, establishment
of traceability system is essential for preventing hazard
Units Units dispersion and decrease of productivity. Therefore,
technology of traceability is focused as the subject of
new research project. One of solutions for the control
Fig. 8 Structured products presentation products traceability with ubiquitous technology in

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supply chain, from parts vendor to nodes of industrial
control systems, is discussed.

Acknowledgement

The projects of NECA were carried out with an

extensive support of many organizations and people.
The author would like to thank the committee of NECA
Standard Certification, Research and Development
Project, the project following up committee, and give
special thanks to IEC TC44, TC65, SC17B, TC94,
ACOS, and METI.

References

[1] Project report of NECA, 2007.March

[2] High-Level Group Report EC, 2004.Nov.
[3] ETPIS Report, 2006.Jan.
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Sakamura 2005.10.30 NTT publishing
[5] TRONWARE VOL.102
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Ron Bell
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[8] INSTRUMENTATION ENGINEERING
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Marine Science and Technology
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NECA
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2007.5.21 Japan Standard Association
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INFORMATION-TECHNOLOGY PROMOTIOM
AGENCY JAPAN
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AGENCY, 2007.May
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