DEVELOP TRAINER FOR

FINDING RANK A MACHINE

SAFETY EQUIPMENT

Assembly Shop Department

(FY 2012)
 Purpose of Machine Safety
In order to strengthen the machine safety in Assembly
Shop for prevent hazard that occur from machine operation.

Objective of Machine Safety

1) Built up machine risk assessor at Assembly Shop
2) Find out potential hazard risk that caused by machine
3) Eliminate or minimize potential hazard risk by
countermeasure activity
 Names Trainer for Machine Safety
No. Name Photo Section Position

1. Wan Nurfadhilah Binti Wan Sazali L1 Technical Planner

2. Mohamad Fauzi Bin Sallehan L1 Prod Group Leader

3. Azrin Bin Abdul Rahman KIJ Technical Senior Executive

4. Mohd Najib Bin Mohd Dahur L2 Line Team Leader

5. Mohd Ismawi Bin Mohd Munawar L2 Technical Executive

6. Muhamad Zul Hilmi Bin Jamaludin L3 Technical Senior Engineer

7. Mohd Zailani Bin Mustafa L3 Technical Planner

8. Mohd Afandi Bin Awang QG Chief Leader

Machine Safety Introduction
Program course
Days Time Content
Part 1 : Class room ( 2 Days )
1) Introduction of safety standard
2) Safety Standard for “ Safeguarding ” of Machines

3) Safety Standard for “ Energy Source Disconnection/Stopping ” of Machine

4) Safety Standard for “ Protection Against Inadvertent Start up ”of Machine

1st Day 1 Hour
5) Safety Standard for “ Start-up ” of Machine

6) Robot Related Measure Standard

7) Electricity related measure

8) Safety standard for stair and ladder

9) Machine safety audit procedure

2nd Days 1 Hour 10) Examination Test

11) Discussion

Part 2 : Practice ( 1 Day )

1) Practical onsite
3rdDays 2 Hours
2) Audit result & discussion (Included final report)

1) Practical onsite
4 Days
th
2 Hours
2) Audit result & discussion (Included final report)
Machine Safety Introduction
1 Image Content

Safeguarding of machine Power source disconnection

/ stopping of machine

Protection Against Inadvertent Start up Start up of machine Robot related measure

of machine
Primary Risk: “Severity” and “probability” of accident
cable
Power
switching gear IV. Probability of harm
III. Possibility of
Interlocke avoidance/restriction
Live d door
part
cove
r
II. Frequency and I. Severity of harm
duration of exposure
Grounding Terminal
block

Electrical related measure Stair & ladder M/C Risk assessment

2 Self Practical Audit Activity

Purpose : To level up machine safety audit skill and experience for trainers

-Select machine for practice

-Set up the practice team
Preparation (4-8 persons/team)
-M/C Layout & Document

-Hazard identify
Practice Audit -Risk evaluate
< M/C risk Assessment >
-Risk reduction plan

-Summarize practice audit result

Summary Report -Discuss result in each team

-Present and share result to other team

Present & Discussion -All members discussion
 3 Joint Machine Safety Audit
Purpose : Find out potential hazard risk that caused by machine

Action :
1) Establish Machine Safety Audit Activity

2) Set up Audit Task Team

3) M/C Risk Assessment

4) Risk Reduction Plan

4 < Risk Assessment Step >

Improvement Activity
Purpose : Eliminate or minimize potential hazard risk by risk reduction / countermeasure

Action :
1) Implement Risk Reduction
2) The high risk level (Level 4 - 5) is the first priority to eliminate
 Introduction
of
Machine Safety standard

Safety Promotion Section

Safety and Plant Engineering Department
Toyota Motor Asia Pacific Engineering & Manufacturing Co. Ltd.
 Standardization of Safety Machines
ＴＭＳ :Toyota Manufacturing Standards
ＴＭＲ :Toyota Manufacturing Rules

＜ＩＳＯ (=ＥＮ)＞ ＜ TOYOTA＞

Machine Directive
Low voltage Directive
ＥＭＣ Directive
Fundamenta l Safety Standard
ISO１２１００
ISO１４１２１
B1:Particular Safety Aspects
B2:Safety Related Devices
Safety Requirements
ｆ or a Particular Machine
or Group of Machines
Ａ１： Fundamental standards
for safety equipment
Ａ２： Fundamental standards for
safety equipment (each hazards)
TMS QSS0100n～ 0400n
Type Ａ TMR QSS0100s～ 0200n
Ｂ１： Database for inherently safe
Group Safety Standard
Ｂ２： Use & spec. for Safety devices
Type Ｂ
Ｃ１： Standards for Individual machines
Machine Safety Standard － Conveyor
－ robot
Type Ｃ Ｃ２：※ＭＳ /※MR
Fundamental Safety Standards
Isolation Startup
Safety guards of machines Startup of machines
(TMS QSS0200n) (TMS QSS0400n)
Now I Configure the
feel circuits and
assured. mechanisms so that
Fundamental Safety Standard the machine cannot
be started without
Isolation from potential Safe startup operator’s intention
hazards of doing so
Startup
Hazard

Elimination of Shutdown state

potential hazard maintained

Energy source Protection against inadvertent

disconnection /shutdown (TMS startup of machine (TMS
QSS0100n)
Emergency stop devices are installed to QSS0300n)
allow the operator who assesses the Install an appropriate device to prevent any
situation to stop the machine. machine from being restarted by any
Stop me person other than the
properly. Emergency operator who stopped
stop the machine.
OK.
Carry out lock-
out operation by
yourself without
fail.

Shutdown Shutdown state maintained

 Safety Standard
for
Safeguarding of Machines
<Refer TMS QSS0200n, TMS SQI0200n>

Now I feel
assured.
Content
● Basic point for protective measure
● Selection of safeguarding measure
● Fixed guard
● Moveable guard
● Electro sensitive protective equipment (ESPE)
● Two-hand control device
● Installation requirement for safeguard
● Additional protective measure at a gateway provided for transport
carrier to pass through
● Additional requirement for ESPE in hazard zone
Basic Point for Protective Measure

1. Safe machines (Inherently Safe Design measure)

NG

2. Safety guard

2.1) Setting of movable range

Next Step

2.2) Implementation of safety guards

If safety guard is difficult to implement or Low risk

3. Reduction of damage
Take appropriate measure to stop the machine immediately if a person come in contact with it.

If it is difficult to achieve with any technology currently available

4. Protective measures involving person’s careful attention

1. Safe machines (Inherently Safe Design measure)
Machines shall be designed to be safe that is as free as possible from
hazards caused by energy driven and to be low in risks.
The requirement as following;
a) Elimination or reduction of the number of
energy sources.
b) Reduction of energy source requirement to a level
as not to cause harm to the human body.
 Motor output rating: 80 W max.
 Thrust force: 75 N max.

c) Possibility of avoidance
 Operating speed of moving part
(for safety purposes)
: 250 mm/s max.
 d) Structure/design that does not cause harm to human body.
(A) Gap to avoid crush (B) Each machine shall be free of
Body parts Min. Space (mm) Example sharp-edged ends/corners and
protrusions, and shall not have parts
Body 500
that can catch parts of human body
Head 300 or clothes, etc.

Legs 180

Limbs 120

Toes 50

Arms 120

Hands 100

Fingers 25

If it is difficult to eliminate hazards or sufficiently reduce risks by any

measure provided as above mention, Safety Guard shall be implemented.
2. Safety guard
2.1) Setting of movable range <Setting of movable range>

Limit the maximum area in which the Movable

range
machine can move, so as to prevent the
machine from violation the operator zone
Machine
by using order of priority below; 500 mm

Isolation zone
a) Mechanical Stopper

Electrical Stoppers, if used, shall meet all of the

following requirements.
Mechanical Mechanical  The device shall be a limit switch.
stopper stopper  A protective stop shall occur upon detection.
b) Electrical Stopper  Configure the circuit so that a protective stop
occurs in the event of disconnection.
 Ensure that the machine overrunning the limit can
be manually returned to the home position without
using motive power.

Limit SW. Limit SW.

2.2) Implementation of safety guards
Safety guards shall be implemented to prevent contact between the
machine and persons.
a) The Isolation zone shall be set to enclose the movable range.
b) The safety guard shall be valid in all mode.
c) Safety guards shall be selected, with consideration given
also to object possibly falling or being ejected from
the machine. Movable range
(Danger zone)
All above are implemented in case of the
movable range is not higher than 2500mm from
surface on which persons can stand. 2500 mm
min.
(2.2.1) Measures for prevention of access from the surrounding area
< Fixed Guard >
- Safety Fence
- Safety Cover

(2.2.2) Measures for prevention of access through an opening

< Movable Guard > < ESPE >
- Interlocking guard - Light curtain
- Movable cover - Safety Mat
- Laser Scanner
3) Reduction of damage
If it is difficult to set the isolation zone and risk is low, an appropriate
protective measure shall be taken to ensure that the machine stops
immediately when a person comes in contact with the machine .

Example in case of difficult to set isolate zone

Automated Guided Vehicle.<AGV>

a) The protective measure shall prevent persons from being injured if they are
caught in machine operated by motive power or inertial force.
b) Detection of contact between the machine and person shall immediately
trigger protective stop.
c) The contact detecting device shall be installed at a location where detect
contact of person without fail in any position or posture.
d) Contact shall not cause a secondary accident (tipping of machine)
4) Protective measures by involving person’s careful attention
If after implement of safety guard, it is still difficult to ensure safety for some
operation, it become necessary to take additional measure regarding the
administrative system. Such as Crane Operation, Forklift Operation

(1) Operators shall be qualified

(2) Work manual shall be established

(3) Education/Training shall be implemented

(Include Personal Protective Equipment, PPE)
Selection of Safeguarding measure
1) Appropriate safeguard as the flowchart following;

Fixed guard

Interlocked guard

1 2
1 2

Interlocked guard

Electro sensitive Two hand control

protective device device
2) List of Safety guard

Definition
Fixed guard
A fixed guard shall be the first-priority choice for safeguarding
• Protective fence (Safety Fence)

• Protective Cover (Safety Cover)

• Fixed guard installation requirement:
• Fixed guard functional requirement:
a) It shall be constructed for using only tools to remove and shall not
be able to be loosened or removed by fingers or coins.
b) The strength of a fixed guard shall be considered as following;
• Providing for the possibility that a person may
fall against the guard, it shall be to endure a
F = 1000N
horizontal force of 1000N applied at a height
h = 1000mm
of 1000 mm. above the floor surface.
• If there is the possibility that machine parts, work-piece, tool
are thrown from the machine, It is necessary to conducting a
risk assessment and the fixed guard must be strong enough.
c) A fixed guard shall be designed so as not to obstruct the view of
the machine inside.
Movable guard
When necessary to access the hazard zone, a movable guard, such as
a door, should be installed on the fixed guard.

Fixed guard

> 600mm

Movable guard
• Movable guard installation requirement:

a) If whole body access is permitted, the width of the gateway shall be

600 mm. or more for easy entry and exit.
b) If the machine cannot stop immediately after protective stop, and
power-lock type interlocked guard shall be installed which
enables unlocking only after confirmation that the machine is
standstill status.
c) It shall be constructed for using only tools to remove and shall not
be able to be loosened or removed by fingers or coins.
d) If whole body access through the gateway, interlocking device with
a locking function for prevent inadvertent start up and enable escape
from the hazard zone should be provided.
• Movable guard functional requirement:
M/C Stop
a) The device shall trigger machine to make a protective
stop when the interlocking guard is opened.
b) Interlocked guard shall comply; Opened

• Machine cannot started while the guard is opened.

• When the guard is closed, machine becomes operable but
does not start automatically.
c) Power-lock type interlocked guard shall comply;
• Machine cannot started while the guard is opened
• The guard remains closed and latched until all risk have been
eliminated.
• When the guard is closed, machine becomes operable but
does not start automatically.
• Latching shall remain even if the power of machine is cut.
d) For prevent parts of the human body from being caught in the
closing guard as following;
• The thrust and driving energy of the movable guard shall not
exceed 75N and 4J.
• If above cannot be met, the movable guard
F = 75N
shall be equipped with a protective device that
can trigger a protective stop. So the thrust to
prevent closing and driving energy of movable
guard shall not exceed 150N and 10J.
• The movable guard shall be configured so as not to catch
parts of the human body or clothing.
• The movable guard that opens/closes vertically shall be
equipped with an anti-drop mechanism.
 Install interlock device < Movable guard >
at open side.
1. If the whole body can enter
・ Can lock out
・ Can get out from inside

2. In case of inertia rotation

・ Can open after confirming stop

Power-lock type
interlocked guard
<Electromagnetic
lock-type interlock
device>
Electro sensitive Protective Equipment (ESPE)

Optoelectronic safety device (Light curtain)

• Electrosensitive protective
devices are used where the
machine is frequently accessed,
as with a machine operating
continuously on a cycle by cycle
basis.

Pressure sensitive mat

(Safety mat switch)
ESPE can detect the whole or part of the human body shall be installed
At the opening of a fixed guard. Classification as following;
• Light curtain : sensing function is performed by
optoelectronic emitting and receiving elements
detecting the interruption of optical radiations
Light curtain
generated.
• Pressure sensitive mat (Safety mat) : to detect a
person who standing/step on it, responds to pressure. Safety Mat

• Laser scanner : the sensing function is same as light

curtain but it detects the diffuse reflection of optical
radiations generated within the device by an object
present in a detection zone specified in two Laser Scanner

dimensions.
• ESPE installation requirement:
a) A Opening shall be appropriate size for job
b) An appropriate safety distance in accordance
Safety distance
with the stopping time of the machine shall be
provided for prevent an operator from reaching
the hazard zone before machine stops.
c) ESPE can detect entry of persons without fail.
d) Opening for passing carriers, persons cannot
pass through the opening together with transport
carrier and parts of human body cannot be
caught in the movable part of transport carrier or
between the movable part and any stationary part of machine.
• ESPE functional requirement:
a) It will trigger protective stop when detecting
a person or an object unless being muted.
b) When detected, It shall not be able to reset
a protective stop of the machine unless
being muted.
c) Detecting nothing shall not cause the machine to be automatically
restarted.
d) A function to maintain the protective stop signal is required until the
reset button is pressed .
e) An indicator signal shall be provided to show when an
ESPE detects an object while the machine is powered on.
Two-hand Control Device

• Two-hand Control Device installation requirement:

a) This device is intended for protection only of the person operation and
for the machine that access high frequency, risk of injury is acceptable
and no persons other than the operator.
b) The number of the devices shall be determined based on RA
c) An appropriated safety distance shall be provided.
• Two-hand Control Device functional requirement:

a) It shall comprise two start pushbuttons (input section) and a control.

b) Two signal inputs through the two pushbuttons shall cause the
machine to be started.
c) Release of either or both of the two pushbuttons shall trigger
protective stop.

d) The machine shall not be started unless the two pushbuttons are
pressed simultaneously or within 500msec of each other.
e) The device shall contain an anti-repeat circuit.

f) The specifications of a two-hand control device shall be designed

so as to prevent the invalid pushbutton operations
g) Frequently-used two-hand control devices shall comply with the
following requirements based on perspective of ergonomics;
• The devices are designed for a full hand push.
• The operation force shall be 40 N or less.
• The height of the device shall be between 800 mm and
1000 mm from the reference plane when the device is installed
to be operated from above.
F = 40N or less

h = 800-1000mm
Table : Invalid operation Pattern to be considered and specifications
Table : Invalid operation Pattern to be considered and specificationsª (continued)
 Installation Requirement for safeguard
When installing a guard. It is necessary to provide an
Appropriate safety distance of the guard. For prevent
the operator’s limbs from extending through the guard
or reaching the hazard zone.
1) Reaching over the guard to the hazard zone (Upper Limbs)
Table : Safety Distance for the case where the danger zone can be reached over the guard
when the risk is low

“The risk is low” mean that the severity of harm is Low (very minor injury or injury not
Requiring absence from work.
Table : Safety Distance for the case where the danger zone can be reached over the guard
when the risk is high

(Above table) :
Example 1, If the height of the hazard zone is 1400 mm. and the horizontal
Guard
distance from the guard to the hazard zone is 900 mm.
the
guard shall be 1600 mm. or higher.
1600 1400

Ex.1 900
2) Reaching through openings to the danger zone (Upper Limbs)
Table : Safety Distance for the case where the danger zone can be reached though openings.

(d)
Opening

(Above table) :
Example, If each opening is a rectangle whose narrow side is 15 mm. long, the horizontal
distance from the guard to the hazard zone shall be 120 mm. or more.
3) Reaching through openings to the danger zone (Lower Limbs)
Table : Safety Distance for the case where the hazard zone, can be reached through opening.
4) Safety Distance
If ESPE or a two-hand control device is installed for the purpose of
detection of entry, an appropriate safety distance shall be
determined
as following, to provide for the possibility that person reaches the
hazard zone during the time lag from detection of the person to the
protective stop of the machine;
S = K x T + C --------- equation (1)

S = Safety distance
K = Approach speed of the whole or part (hand, finger, etc.) of the human body (mm/s)
T = Time for device to respond (t1) + Time for machine to stop (t2) (sec)
C = Reachable distance from out of the detection zone including undetectable area.

Optoelectronic
safety device T = t1 + t2
4.1) Safety distance of Light curtain
Safety distance S from the detection zone, If the angle of the approaching
direction with respect to the detection zone is 30 degree or larger ;
S can be calculated with the following values substituted in equation(1) :

K = 2000 mm/s K = the speed of the human hand moving

C = 8 x (d – 14 ) d = Diameter of the smallest detectable object.

Reaching from the detection zone

Example : If the time to electric response is 0.05 s, the diameter of the smallest
detectable object being 30mm., the time to protective stop
being 0.06s., then the safety distance is as following;
S = (2000 x (0.05+0.06) + 8 x (30-14)
= 348 mm.
When the approaching direction is parallel to the detection zone. If the
angle of the approaching direction with respect to the detection zone less
than 30 degree the safety distance S shall be calculated with the following
values substituted in equation as 1)

Reaching at a parallel detection zone

K = 1600 mm/s K = the speed of human walking

C = 1200 – 0.4H H = Height of the detection zone above reference

plan (mm.)
Note: The value H shall be 300 mm or less to prevent creeping under the
detection zone to enter the hazard zone.
4.2) Safety distance of Pressure Sensitive Mat (Safety Mat)
S can be calculated with the following values substituted in equation(1) :

K = 1600 mm/s
C = 1200 mm.
Appropriate measures shall be taken to prevent
easy entry to the hazard zone through an open
space on each lateral side of the mat.
Example usage of pressure
4.3) Safety distance of Two-Hand Control Device sensitive mat

S can be calculated with the following values substituted in equation(1) :

K = 1600 mm/s
C = 250 mm.
When used as a safeguarding device, the
position or the two-hand control must be
Case where a two-hand control
placed so that the safe distance is measured
device is used
from the closest hand control to hazard.
Additional Protective Measure at a Gateway provided
for Transport carrier to pass though
When an ESPE or the like intended for prevention of
human entry is installed at an opening provided for
the entry of a carrier or AGV, it is necessary to mute
the ESPE or the like temporarily at the instant the
carrier or AGV passes the opening.

1) Set the width of gateway to allow a small clearance

of 120 mm. or less between a transport carrier
and the fixed structure at the gateway.
And countermeasure such as a retractable guards
shall be installed to prevent a person be
caught between the transport carrier and
the fixed structure.
2) In case of person walk in to the machine zone
through the gateway together with a transport
carrier, Set the width of the gateway to allow a
clearance of 500mm or more between a transport
carrier and the fixed structure for prevent a person
be caught and install an appropriate protective
measure (such as a pressure sensitive mat) to
substitute the muted interlocking device or ESPE
3) The interlocking device or ESPE is muted when
the front end of a transport carrier reaches a
certain point before the interlocking device,
and un-muted when rear end of a transport carrier
passing through the gateway, the distance between
them shall be set at 120 mm. or less.
Additional Requirement for ESPE in hazard zone
Where ESPE is installed in hazard zone to separate the zone, the
Following requirement are applied in addition.
M/C A

Light curtains as separator Risk after locking out

a) An appropriate safety distance shall be

provided to prevent the possibility of a
person reaching the hazard zone
during the time lag from detection of the
person to protective stop of the machine.
b) Even if the power of the adjacent machines is
disconnected, the power to the ESPEs to act
as separators shall be available for the machines
so that machine can be operated.

c) When ESPE is installed in a movable range of a robot, additional devices

shall be installed to limit the movement of the robot and keep a safety
distance.
d) Although four ESPEs are required to be installed based on b) above
for detection of human and c) for limitation of robots that the movable
range includes the other zone.

A Zone
 Safety Standard
for
Energy source
Disconnection/Stopping
of Machine
<Refer TMS QSS0100n>

Stop me
properly. Emergency
stop OK.
Content
● Purpose of Energy source disconnection/stopping measure
● Design concept of energy source disconnection/stopping measures
● Function of energy source disconnection/stopping
● Energy source disconnection
● Emergency stop
● Protective stop
● Requirements regarding machine stop method
Basic Safety Standard for Energy Source
Disconnection/Stopping of Machines
1. Purpose of Energy source disconnection/stopping measure
The energy source disconnection and stopping devices are
installed to enable operators to stop each machine for prevent
power-operation accidents (including electric shocks) involving
persons who enter the machine work zone.

2. Design concept of Energy Source Disconnection/Stopping

Measures
When there is a possibility of contact between persons and a
machine, it’s necessary to take energy disconnect/stop measures
as follows to prevent the machine from moving.
<Source of power>
Electricity Air pressure Gas, material,
② Emergency stop
Energy source Operation panel
① disconnection
Manual master
Circuit breaker valve
Emergency
stop button
Power control elements

Electromagnetic Air solenoid selector

③ Protective stop
switching device Safety relay unit.
valve

Optoelectronic
safety device
Electric motor etc. Air cylinder

Safety Mat
Switch Interlock device

Types of Energy Source Disconnection/Stopping Device

Function of Energy Source Disconnection/Stopping
3. Energy source disconnection
< Circuit Breaker >
This ensures
Z’s
safety.

< Manual Master Valve >

3.1 Requirements of Energy Source Disconnecting devices
a) It shall provide the function of disconnecting external
energy sources from the machine.
b) It shall be installed for each source of energy to be
supplied to the machine.
c) It shall provide the function for releasing energy stored in the
machine (i.e., residual pressure, capacitor charge, etc.) that
remains after supply disconnection. If the residual energy is
remote device, a warning stating the presence of residual
energy shall be posted on or near the energy source
disconnecting device (on nameplates etc.).
d) If hazards could be caused by disconnecting external power
supplied or releasing residual energy, appropriate measures
shall be taken to prevent occurrence of that hazards.
 e) The supply-disconnecting device shall contain devices that
can be operated manually and directly by an operator to
disconnect the energy sources and release residual energy.
f) The energy source disconnecting device shall have the
capability of being locked out.

3.2 Installation Location of Energy Source Disconnecting Devices

An energy source disconnecting device shall be installed at a
location where it can be recognized and operated easily and it
cannot cause hazards.
4. Emergency Stop
4.1 Restriction on Terminology
a) The term “emergency stop” itself (It shall not be
used for the names of device, circuits etc.)
b) Emergency stop device (Red mushroom button
with yellow background or Red pull cord)
As above shall not be used for any function other than the E-stop
function. Oh, it’s dangerous.
Help!
4.2 Emergency Stop Requirements
a) Operating an emergency stop device shall cause the
applicable machine to shut down completely and promptly,
overriding all other functions and operations.
b) It’s essential to provide measures for preventing incorrect
operation of an emergency stop device or misunderstanding
of the affected shutdown area by operators.
c) It’s necessary to eliminate the causes of various worries.
Operator should not think that stopping a machine may
make restoration of energy difficult or may cause additional
hazards and problems.
d) It’s necessary to improve the operability of emergency stop
devices.
4.3 Emergency functional requirements
a) Resetting of an emergency stop device must not cause the
applicable machine to restart.
b) The emergency stop function must be affective in stop category
0 or 1.
c) The reliability of an emergency stop system must be selected in
accordance with the risk level of applicable machines. The
control category must be 2 or higher.
< Stop Category >
Stop categories represent the manner that, after a stop command is
issued, machine actuators, such as a motor or cylinder, actually come to a
stop. More specifically, the following three categories are specified.

Category 0 Stop: Machine is stopped by directly shutting down the

power source of the machine actuator.

Category 1 Stop: Achieved with power remaining to the machine

actuators. Power is removed after the stop is achieved.
Example: Regenerative brake of robot arm.

Category 2 Stop: A controlled stop with power left available to the

machine actuators. Example: Stop in wait status.
< Control Category Selection >
Carry out machine risk assessment by choose control categories based
on the assessment results, as shown below; And control categories are
classified into five ranks (B, 1, 2, 3, and 4).
< Detailed Descriptions of Control Categories >
Requirements of each control category are shown below.
Requirements of each control category (continued)
Categories Concept:
Characteristic
Control Safety
Weak Point
Categories Safety Device Circuit reliability

B - Use normal electrical - Safety functions can Low

devices as safety be lost because of
-
devices ex; use limit trouble.
switch (LS) for E-stop.
1 - Use well tried part for - The probability of - Circuit cannot check
safety device. trouble is lower than fault when it’s
category B welded.
2 - Use certified part for - Single circuit for - Unable to check
safety device. checking fault before fault If welded circuit
push master on. occurred after push
master on.
3 - Use certified part for - Duplicated circuits - Unable to check
safety device. for checking single fault if welded circuit
fault. more than one.
4 - Use certified part for - Double circuits
safety device. - Real time check; no -
matter what any fault
condition, before or
after started. High
Power-source-specific Control Category Requirements and Examples
< Electricity >
An electromagnetic switching device (magnetic switch, relay) shall be
used to shut off power supply.
Category- 2 requirements
 Well-tried safety principles
 Use of certified parts
(safety relay unit, force guided emergency stop button) ... 
 Circuit with a safety confirmation function
(use of B-contact of emergency stop button or A-contact of relay) ... 
 Checks at adequate intervals with the control system
 Back-checks (Off-Checks) of relays and magnetic switches carried out
during Master On ... 
①,②  Safety relay unit < Example of avoidable fault in category 2 >
Emergency stop
CR3 CR1M

CR1M
If the contact at (a) is welded
Master On (b) before Master On, the contact at
MS1 CR1M CR3
(b), which is a force-guided safety
③ [Operation
relay, remains open. Therefore, the
CR1M GN
preparation
lamp]
master on circuit does not become
(a) ON, allowing the operator to detect
CR1M CR3 MS1
(Startup
condition) the fault.
MS1
× I>

× I> M1
× I>
< Example of unavoidable fault in category 2 >
Emergency stop (d)
CR3 CR1M
If the contact at (c) becomes welded
Master On
CR1M after Master On button is pressed,
MS1 CR1M CR3 contact (d) remains ON even if the
emergency stop button is pressed to
CR1M GN [Operation de-energize the CR1M coil at (d).
preparation
(c) lamp] Therefore, MS1 cannot be turned
(Startup CR1M CR3 MS1
condition) OFF. In this situation, it is not possible
to detect the fault.

(e) (f)
Emergency stop Since a short-circuit occurs across the
CR3 CR1M
emergency stop button at (e), the coil
CR1M at (f) remains energized. As a result,
Master On
CR3
regardless of whether the fault occurs
MS1 CR1M
before or after the pressing of the
(g)
CR1M GN [Operation
master on button, MS1 at (g) cannot be
preparation
lamp]
turned OFF even if the emergency stop
(Startup CR1M CR3 MS1 button is pressed. The fault is not
condition)
detectable under this condition.
Category- 3 requirements
 Category-2 requirements shall be fulfilled.
 A single fault in any area does not lead to the loss of safety functions.
 Duplication of circuits and devices
(contacts of emergency stop button, relays, magnetic switches, etc.) ... 
 A single fault is detected whenever reasonably practicable.
 Back-checks (Off-Checks) of relays and magnetic switches carried out
during Master On ... 
①
Emergency stop
CR1M-1
CR3

CR1M-1

CR3 CR1M-2

② CR1M-2
Master On

MS1 MS2 CR1M-1 CR1M-2 CR3

CR1M-1 CR1M-2 GN [Operation

preparation
lamp]
CR1M-1 CR1M-2 CR3 MS1
(Startup
condition)
MS2

MS1 MS2
× I>

×
×
I>

I>
M1
< Circuit Sample >
< Example of avoidable fault in category 3 >

(a)
Emergency stop
CR1M-1
CR3
If a short-circuit occurs across the
CR1M-1 (c) contact at (a), the contact at (b) remains
(b) CR3 CR1M-2
effective due to the redundancy of the
CR1M-2 emergency stop circuit. Therefore, even
Master On
after master on button is pressed,
CR3
MS1 MS2 CR1M-1 CR1M-2
pressing of the emergency stop button
[Operation
causes the coil at (c) to be energized,
CR1M-1 CR1M-2 GN
preparation and therefore the contact at (d) to open.
(d) lamp]
CR1M-1 CR1M-2 CR3 MS1
Consequently, MS1 and MS2 are turned
(Startup
condition) OFF allowing the operator to detect the
MS2
fault.
< Example of unavoidable fault in category 3 >
(e)
Emergency stop
(f) (g)
CR1M-1
CR3
The emergency stop button becomes
CR1M-1
(h) disabled due to the short-circuiting at
CR3 CR1M-2
(e) and (f). Since the relays at (g) and
CR1M-2 (h) remain energized, the contacts at
Master On
CR3
(i) and (j) remain ON. As a result,
MS1 MS2 CR1M-1 CR1M-2
MS1 and MS2 cannot be turned OFF.
CR1M-1 CR1M-2 GN [Operation
preparation
lamp]
(Startup CR1M-1 CR1M-2 CR3 MS1
condition)

(i) (j) MS2

Category- 4 requirements
 A single fault in any area does not lead to the loss of safety functions
 A single fault must be detected before or when the next operation of safety
functions is requested. If this detection is not possible, accumulation of
undetected faults must not lead to the loss of safety functions.
 Duplication of circuits of different polarity ... 

Emergency stop
CR3 CR1M-1

CR1M-1

CR1M-2 CR3

CR1M-2 ①
Master On
MS1 MS2 CR1M-1 CR1M-2 CR3

CR1M-1 CR1M-2 GN [Operation

preparation
lamp]

(Startup CR1M-1 CR1M-2 CR3 MS1

condition)
MS2

MS1 MS2
× I>

× I> M1
× I> < Circuit Sample >
< Example of avoidable fault in category 4 >

(c) (c)
× ×

Emergency stop
CR3
CR1M-1
The positions of the emergency stop
CR1M-1
button and coil in the emergency stop
(a) circuit are interchanged to provide
CR1M-2 CR3 redundancy to the circuit. Owing to this
(b) CR1M-2 redundancy, the circuit protector at (c)
Master On
can detect the short-circuiting at (a) and
MS1 MS2 CR1M-1 CR1M-2 CR3
(b), shutting off the power supply to the
entire circuit. Consequently, MS1 and
CR1M-1 CR1M-2 GN [Operation
preparation
MS2 are turned OFF.
lamp]

(Startup CR1M-1 CR1M-2 CR3 MS1

condition)
MS2
< Air Pressure >
An air electromagnetic valve shall be used to shut off air supply.
If actuators be turned off individually, use of a 3-position closed center or
open center air electromagnetic valve is the basic requirement. To shut off
power supply to the entire pneumatic circuit, a 2-position single-solenoid air
electromagnetic valve (spring return) shall be used.
 (1) Category-2
requirement
The position of the air electromagnetic valve shall be monitored.

At dot line, set 2-position single solenoid valve

A (Spring return) with position monitoring function,
perform cutting out of all actuators.
Actuator A corresponds to category 3 level.
B
Incase of air electromagnetic switch valves of
each actuator are 3 position closed center or 3
position open center, each air electromagnetic
C
switch valves is with position monitoring function,
thus even though the whole air pressure circuits
are not cut out this will be category 2
Position
monitoring
① function
2-position single
solenoid valve (Spring
return)
 (2) Category-3 requirements
Provide redundancy to air electromagnetic valves by any one of the following
methods.
1) Install two air electromagnetic valves connected in series to shut off power
supply to the entire pneumatic circuit.
2) In addition to the air electromagnetic valve for each actuator, install an air
electromagnetic valve to shut off power supply to the entire pneumatic circuit.
3) Install two air electromagnetic valves connected in series for each actuator.
 At dot line, set double of 2-position single solenoid
valve (Spring return) without position monitoring
A
function, perform cutting out of all actuators.

Incase of air electromagnetic switch valves of

B each actuator are either 3 position closed center
or 3 position open center, the above 2-position
single solenoid valve (spring return) can be 1
layer.
C

②
2-position single
solenoid valve (Spring
return)
(3) Category-4 requirements

Monitor the position of each redundant air electromagnetic valve.

At dot line, set double of 2-position single solenoid

valve (Spring return) with position monitoring
function, perform cutting out of all actuators.

Position
monitoring
③ function
2-position single
solenoid valve (Spring
return)
4.4 Requirements of emergency stop device
An acceptable emergency stop device shall be selected and
installed as follows;
a) Standard emergency stop device specified in the appropriate
TMS.
b) An emergency stop device shall be installed in a location
where it can be recognized and operated easily and it cannot
cause hazards;
- Operation panel where the master on button for the
applicable machine is installed (In the case of emergency
stop button)
- Location where operators are positioned to carry out
machine preparation/setup, quality check etc.
- Location where a monitoring supervisor is positioned
during robot teaching.
 - Other locations where installation of an emergency
stop device is considered necessary from the view point of
the purpose of emergency stop.
The specific installation location of the device shall be
determined with approval of all related dept.
c) Pressing of the emergency stop button on an operation panel
must shutdown the applicable machine overriding all other
functions and operations on the operation panel.
d) In the case of emergency pull cord, the following requirements
must be met in addition to the requirement a), b);
- A device to reset emergency stop state must be
installed
in a location where the entire emergency pull cord is visible.
- The wire must be distinguished by the color red (e.g. by
being wrapped in red tube)
4.5 Configuration of Emergency Stop Area
The emergency stop area of each machine/system shall be set
as follows in accordance with the control/isolation configuration of
the machine/system
(1) Case where Isolation Zone Coincides with Control Zone

a) Emergency stop area shall be set for each control

(isolation) zone.
b) Emergency stop of a particular machine shall not cause
machines in other control (isolation) zone to shut down
(2) Case Where an Isolation zone contains Multiple Machines in a
Different Control Zone.

a) All machines arranged in one isolation zone shall make an

emergency stop when any emergency stop device installed
for the isolation zone is operated (Simultaneous shutdown
of machines in on isolation zone)
b) Emergency stop devices shall not be installed for
emergency stop of individual machines.
(3) Case Where an Isolation zone overlaps other machine’s control
zone

• Emergency stop area shall be configured so

that machines A,B and C shall make an
emergency stop within their respective
isolation zones

a) The emergency stop area for the machine is each isolation

zone shall be set in accordance with as case where
isolation zone coincides with control zone.
b) If the control zone for a certain machine overlaps the
isolation zone of other machine, the machine shall make a
protective stop when the emergency stop device for the
isolation zone of other machine is operated.
c) As an alternative measure for b) a mechanical or electronic
stopper may be installed to prevent a machine in the other
control zone from entering the isolation zone for the other
machines.
< Case Where an Isolation Zone overlaps other machine’s control zone (1) >

Conveyor

Emergency stop area

of conveyor

Emergency stop area Emergency stop area

of machine 1 of machine 2

Case 1: Emergency stop button for a processing machine is pressed while a carrier
is present in that processing machine.
Conveyor

• If E-stop button for machine-1 is pressed

E-stop button Transfer device when the movable part of conveyor is in
the isolation zone for machine-1 this
movable part shall make a protective stop
Processing
(apply also to machine-2)
machine
(machine -1)
 Case 2: Emergency stop button for a processing machine is pressed while a
transfer device is present outside that processing machine.

Can’t go
• If the E-stop button for machine-1 is
ahead.
pressed when the movable part of conveyor
E-stop button
is outside the isolation zone
for machine -1, a mechanical or electronic
stopper shall work to prevent this movable
M/C -1 part from entering the isolation zone for
machine-1 (Apply to machine-2)
< Case Where an Isolation Zone overlaps other machine’s control zone (2) >

• When emergency stop button A is pressed,

all the Machines and any transfer cart in
isolation zone A come to an emergency stop.
However, the machines in isolation zone B will
not be brought to an emergency stop.
• When an emergency stop occurs in isolation
zone B, a signal sent from machine B will bring
the transfer cart in zone A to a protective stop
to prevent the cart from entering zone B.

If when a transfer cart is entering isolation zone

B, an emergency stop occurs in zone B, the
cart comes to an emergency stop.
Furthermore, a protective stop occurs in zone A
because the transfer cart breaks the light
beams of the optoelectronic safety device
installed between zones A and B.
4.6 Indication of Emergency stop area
a) The frames etc. of machines that can be shut down by the E-stop
device on a particular operation panel shall be painted in the same
color as the operation panel to indicate the E-stop area.
b) The machines to be shut down by the E-stop device on a particular
operation panel shall be indicated on a nameplate, which shall be
attached to the operation panel near the E-stop device
5. Protective Stop
5.1 Basic Requirements for Protective Stop
a) The protective stop system shall provide the
same or equivalent equipment configuration
and performance as the emergency stop
system.
b) A power supply circuit shall be connected to the protective
stop circuit to enable the protective stop system to shut
down machines in the same state as by the emergency stop
system to provide for the following cases;
- It’s necessary to set work pieces repeatedly and
frequently for each cycle of operation in machines
that can be operated continuously or automatically.
- Machines need to be shut down for protection,
using and interlock signal sent from a relevant machine (to
secure the safety)
5.2 Functional Requirements of Protective Stop
a) The reliability of protective stop must be selected in
accordance with the risk level of applicable machines. The
control category must be 2 or higher.
b) The protective stop function must be effective in stop
category 0 or 1.

5.3 Requirements of Protective device

a) Protective devices selected from the following shall be used:
- Enabling device (Deadman switch)
- Two-hand control device
- Interlocking device (Guard-rail door interlock)
- Electro sensitive protective equipment
(Light curtain, safety mat switch) Enabling device

- Limiting device (Electronic stopper etc.)

- Interlock signal (Signals sent from relevant machines to ensure safety)
b) The machine shall not restart automatically when the stop
signal from a protective device turns off. Where a protective device
is installed at an opening which is large enough for the passage of
a person and is provided for transport carriers to pass through , a
reset device for the protective device other than this standard
mentioning shall be installed at a place where the whole machine
can be seen.
5.4 Configuration of Protective Stop Area
Basically, the protective stop area shall be set under the same
rules as the emergency stop area.
If the protective stop area is restricted, it shall be considered the
purpose of the protective stop.
(1) Case Where Protective stop area coincides with Emergency stop
area
The protective stop area shall be set in accordance with section
4.5 (1),(2) same as emergency stop area.

(1) Case where Isolation Zone Coincides with (2) Case Where an Isolation zone contains
Control Zone Multiple Machines in a Different Control Zone.
(2) Case Where Protective stop works for Part of other machines
within the protective stop area
Protective stop function shall be effective for all machine
actuators within the protective stop area (section 4.5 (3) )
(3) Case Where Protective stop works for Part of Machine
a) The area outside of the protective stop coverage shall be
separated by an appropriate isolation device from the protective
stop area, to ensure the safety of operators in the protective
stop area.
b) The protective stop area shall be set so that a protective
device can detect the access of a person without fail or so that
operator standing at the position of the protective device can
view the entire protective stop area of the machine. If such
setting is impossible, Master On shall be cut off when the
machine has initiated a protective stop.
c) In the case of a protective stop system using a power
supply, if a protective device has been activated then the
power supply is not ready for protective stop, the master on
shall be cut off.
6. Requirements Regarding Machine Stop Method
a) The basic rule is to “stop the source of driving energy”
b) It is permissible to “stop driving–energy transmission” only
if there is no other method to secure the safety of operators
(while ensuring easy restoration of power supply as well) or
protect machines from damage

(a) Stopping the source of driving energy (b) Stopping driving energy transmission
 Safety Standard
for
Protection Against
Inadvertent Start up
of Machine
<Refer TMS QSS0300n>
Content
● Concept of Inadvertent-Startup Prevention
● Basic Points for Inadvertent-startup Preventive Measures
● Measures for Inadvertent-startup Prevention
Basic Standard for Protection against Inadvertent
Startup of Machine (Basic Standard)
To prevent inadvertent startup of
machines for operators who enter the
isolation zone
1. Concept of Inadvertent-startup Prevention
1.1 On Lock-out Huh? The
plug is
missing.
Each operator who enters the machine zone by
himself/herself maintains the machine in
shutdown state by lock-out.
1.2 Purposes of Lock-out Who turned
it off ?
a) To ensure safety in an identical manner for
all operators working in an isolation zone
b) To ensure that the operator who took safety
measures resets the safety measures.
 What is a lock-out system?
It is the rule “To maintain the stop status of a machine with a pad lock” instead
of “Using a mobile plug and tag stating a warning not to switch on”, which has
been implemented as “The rule to prevent wrong operation by others”.
<Previous>

Fundamental Safety Standard

Isolation from potential Safe startup
＆
hazards
Startup
Hazard

<Now>
Elimination of Shutdown state maintained
potential hazard
2. Basic Points for Inadvertent-startup Preventive Measures
Appropriate measures shall be implemented to prevent inadvertent
startup of machines according to the following methods;
a) Operators who enter the isolation zone shall take appropriate
measures by themselves to prevent inadvertent startup.
b) Machines shall be equipped with devices appropriate for the
measures described as a)
c) Rules shall be established, and operators shall be educated
and trained, to ensure proper implementation of measures
described as a)
 Summary: While an operator was checking an irregularity with an injection mold, another operator
who had finished his/her operation started the machine. So the operator was trapped in the mold.

Date May 12, 2005 Place

Bumper Injection Machine at Tsutsumi Injection Factory

Position EX Age 33 years old

Bumper Injection Machine

Bumper
Transporter

Slide Door

Place for molds

Place for molds

Products

Waiting Room
 Mr. B

Mr. A
Means for Prevention of Inadvertent Startup
In the past Now
1st person 1st person
3rd person 2nd person
3rd person 2nd person
3. Measures for Inadvertent-startup Prevention
3.1 Equipment Specification
All machines shall be able to be locked in the
shutdown state using a lock stipulated in TMS
SQH0300n
20.0±1.0

40.0±1.0

6.0±0.3

Up to 50.0

Up to 40.0 Up to 25.0
3.2 Devices to be Locked Out
The following devices shall be equipped with a locking capability;
a) Emergency stop devices installed on operation panels

b) Interlocking devices installed on movable guards, such as

guard-rail doors (excluding the devices installed at an
opening through which operation cannot enter the isolation
zone)

c) Manual master valves installed in accordance with TMS

SNI0002n “Measures for Residual Pressure in Pneumatic
Circuit (common standard)”

d) Power-switching devices installed on control panels

Supplement 1
Supply circuit
disconnecting means
<Equipment-related> for new machine
Electricity

Guard entrance
E
L
Interlock devices Air

Manual
master valve
L Machine
L

Operation panel L
Lockable emergency
stop button
Implementation
-Control panel doors -Main value
-Distribution boards/Bus ducts
Implementation
- Interlocking device - Emergency Stop , Key Switch

Existing Machine Existing Machine

Place Place
metal metal
fitting fitting

Change interlock device for

new machine Change interlock device for
new machine
 Safety Standard
for
Start-up of Machines
<Refer TMS QSS0400n , TMS SQI400n>
Content
● Basic point regarding start-up of machines
● Basic specification of operation devices for starting machine
● Basic requirement for installation of operation device
● Basic specification of control device for starting machine
- Interlock with a safety device
- Prohibition of use of multi positional operation device
- Automatic operation
- Manual operation

● Measure for signaling before startup

- Installation requirements for pre-start alarm devices
- Requirements for hazard escape measures
Basic point regarding start-up of Machines
(1) To start a machine for automatic operation or to activate each
working part of a machine in the manual operation mode, use a
starting device that requires action by operator.

(2) Ensure effective isolation of machine from people at the time of

staring the machine.

(3) Eliminate factors that can cause inadvertent or unsafe human

operation.

(4) The machine layout and configuration shall be such as to enable

operators at the operating position to have a good view of the entire
isolation zone.
Basic specification of operation devices
for starting machine
(1) The device shall be a finger-operated momentary pushbutton switch.

(2) Each operation device shall be protected by a guard ring

against so that it does not allow the machine to start if
an operator inadvertently touches it.
(3) The following types of operation devices shall not be used for
starting a machine.    
 Red mushroom button
 Multi position switch
 Foot switch
X X X XX
 Operation device whose operating surface is red or yellow
 Starting device that produces starting signals to be transmitted
wirelessly, by means of an optical carrier, ultrasonic wave, etc.
 Operation device that can be operated with very little
force or stroke (sheet key switch)
 Before operation During operation After operation

< Momentary push button switch >

These switch return to the original position when the operator withdraws
his/her hand after pressing the switch and therefore eliminate possibilities
of being left in the ON position

The feet can move in response to

Hey,
a simple spontaneous command
of the body. Imagine what will your GL is calling you.
happen if your foot is over a start
switch.

X
Basic requirement for installation of operation device
(1) The operation panel shall be installed outside the isolation zone.

(2) The area around the operation panel shall be illuminated brightly
enough for operators to read the operation nameplate, manual

(3) The nameplate on the operation panel shall bear information about
the area covered by the operation panel

(4) Operation device shall be arranged and adequately labeled.

 Basic specification of control device for starting machine
<Interlock with a safety device>
(1) Master On or Start-up operation shall not cause the
machine to start unless safety has been confirmed with a safety
device installed as a measure for isolating machine hazards
from people.
(2) After emergency stop of a machine, the master on shall not be able
to be turned on to restart the machine until after the emergency stop
status is intentionally reset by an operator.
(3) The above mentioned resetting operation alone or turning on of the
Master on alone shall not cause the machine to start

<Prohibition of use of multi positional operation device>

1) No starting device for a machine shall have multiple function.

2) Two or more operation device that have the same function or activate
the same moving part shall not be installed on the same machine.
 <Automatic Operation>
1) Automatic single cycle operation shall incorporate an anti-repeat
circuit
2) Operating the start switch for automatic single cycle operation shall
initiate the first step of a cycle without delay.
<Manual Operation>
All machine with automatic operation capability shall also be operable
in the manual mode to enable operators to safely carry out maintenance
adjustment, abnormality recovery of the machines.
(1) Each machine actuator shall be capable of being activated
individually.
(2) Any moving part, if stopping halfway due to a problem, can be moved
back freely in the opposite direction.
(3) Any working part moves promptly when the appropriate manual
operation device is operated.
(4) All manual operation device shall be installed at positions where
operator can easily see the status of the work piece being processed.

(5) Micro inching of each working part shall be possible, providing for
the case where the machine operated in the manual move too fast
for the operator to keep up with, which is very dangerous.
Measure for Signaling before Startup
Remember that someone may remain or step into the isolation zone
when the machine is activated. For a high-risk machine where it is
difficult to confirm whether someone is inside the isolation zone :

 Install a pre-start alarm device, or

 Implement measures to enable people inside the isolation zone to

escape from hazards.

It seems no one is
in the isolation
zone. Is it safe to
run the machine?
(1) Installation Requirements for Pre-start Alarm Devices

Startup signaling Master ON

Startup
30 s or less

Start up
Pre-start alarm Master ON

Resetting
protection
device
Pressing for 10 s
or more 30 s or more Reset

Pre-start alarm requirements Provide a sufficient Thoroughly Operation

 Alarm by light and sound time allowance for ensure a series preparation is not
 Perceivable from anywhere in operators remaining in of operations achieved unless the
the isolation zone the isolation zone to from pre-start alarm is finished.
 Use of the alarm sound for no escape safely from alarm to
other purposes hazards startup.

- The pre-start alarm device shall produce with auditory and visual
alarm signals.
- The auditory alarm signal do not use for other purposes.
 <Installation location and other requirements for Alarms>
a) Auditory signal must be audible at any point within the machine
zone, The volume must be loud enough (background noise
+ 15dB(A) or greater) to clearly audible at any point in the movable
range of the machine.
b) Visual signal must be visible from any point in the movable range
of the machine.
(2) Requirements for Hazard Escape Measures
 Provide an Evacuation space and an appropriate means of
relocation.

 Install an appropriate Safety device with an Emergency stop function

in each isolation zone to enable operators inside to stop the machine
in an emergency.
Robot related measure
Standard

<Refer TMS SQI0001n>

Content
● Definition of terms
● Safety Protection of Robot
- Power shutdown and stopping measure
- Isolate measure
- Measure to protect miss operation of another person
- Measure to protect when start up
- Indication
● Safety requirement for teaching inside isolation space
Definition of terms
 Term Definition Supplement
Maximum space Area reached with moving parts of robot
and the reached with end - effecter
and/or workpiece
Movable space Part of maximum space; area in which Restricted space
the robot moves during operation at the
maximum speed with a rated load
(Including the breaking distance)
(Including the area reached with the end
– effecter and/or workpiece).
The area can be limited by mechanical or
electrical stopper.
Operational space Part of movable space ; area reached Area reached by robot
during operation under a program. or workpiece in
automatic mode;
moving range specified
in earlier standards
Isolation space Area enclosed with safeguard Safeguarded space

End-effecter Part of the robot directly acting on the

object of work
Safety Protection of Robot
1) Power shutdown and stopping measure

(a) Install an emergency stop device on the robot operation panel.

(b) The safety related section of the robot (emergency stop device,
protective device) shall satisfy the requirement of control category
3 or higher.
(c) The emergency stop device shall function in all operation modes.
It shall remain effective to other machines in the same isolation
space even after the robot control power is turned off.

(d) The protective stop device shall function in all operation modes
however, this is inapplicable to the movable guard for teaching
inside the fence. (movable door for entering the isolation space
to teach the robot.)
(e) The emergency stop device and protective device shall have a
structure where its function can not be disabled through a jumper
pin, selection switch or the like.

(f) The robot shall have a structure to stop immediately with a brake
or the like and keep holding the workpiece or sustaining its arm
even in power shutdown, emergency stop or protective stop state.
2) Isolate measure
For measure implementation, Shall follow TMS QSS0200n and
TMS SQI0200n,
(2.1) Movable space setting

(a) The 1st axis of the robot shall be provided with a mechanical
stopper. The 2nd and 3rd axis shall be provided with mechanical
stopper or electrical stopper (such as limit switch)
(b) If the movable space varies according to movement of axis other
than the above-mentioned three axis, the axis shall be provided
with a mechanical or electrical stopper also.

(c) The mechanical stopper shall stand the impact of the maximum
thrust at the maximum speed with the rated load of the
corresponding actuator.
(d) The electrical stopper used for the setting of the movable space
shall have control category 3 or higher reliability and it shall stop
power supply to the robot upon activation of the corresponding
stopper in a protective stop. The movable space shall be set so
that the robot can be stopped securely within the movable space
even in the event of overrun or other accidents

(e) In case of difficult to install mechanical stopper and electrical

stopper for another axis beside 1st axis, It’s possible to set movable
space by use soft limit, But must meet all the following necessary
condition;

 The robot shall be configured with a control system that has

control category 3 or higher reliability authenticated by an
external certification.
 The movable space setting shall be difficult to change
  The movable space shall be set so that the robot can be stopped
securely within the movable space even in the event of overrun
or other accident.

 The planning dept. shall clearly present to the operating dept.

The method for checking the soft limit function.

(f) The movable space shall include the moving space of the working
piece or end-effecter held by the robot.

(g) The direction of motion of each joint shall be directly indicated on

each axis of the main body of robot.
(2.2) Measure to prevent entering from around machine

(a) Enclose outside of movable space by fix type guard to prevent

human enter into movable space.

(b) Install movable guard for in and out isolation

space when maintenance and shall install
interlock to make all machine stop when
open guard to protection stop

(c) At Opening of process that there are human,

shall compose structure to prevent touching
while automation running and touching to
robot when grasp or release work piece,
compose structure that break power of robot
when human enter.
Example; Use protection device, such as light certain, Safety Mat.
(d) In case of working by move in isolation space to load and unload
work piece at high frequency, compose structure that could
perform work while robot status is power stop or status of operator
and robot is isolated status.
Example; Use protection device such as light curtain to make
isolation to prevent robot move into load/unload zone that human
is entering while running
3) Measure to protect miss operation of another person

Shall implement follow TMS QSS0300n, and Install instrument

that could lock-out the following area,

(a) Emergency stop device that installed on operation panel.

(b) Interlock device which installed at movable guard

(c) Manual master valve

(d) Electrical circuit breaker which install at control panel

(a) (b) (c)

(d)
4) Measure to protect when start up
Shall implement protection measure follow TMS QSS0100n
and TMS QSS0400n
5) Indication
(a) Install indication light (color orange) at position that could
easily see from operation position, teaching position and install on
robot body. Incase of difficult to install directly to robot, install at
position that easily see near each robot.

(b) Indication could confirm that robot is running automatically and

teach mode.
 Safety requirement for teaching inside isolation space

1) Robot operation speed must not over 250 mm/s

2) The robot can operate only when there is a power supply signal from
enabling switch (Dead man switch) of teach pendant for prevent
inadvertent start up without intention.
3) The other operation panel can not operate while using teach pendant
operate by selected teach mode, except emergency stop button.

4) Install structure that can escape from isolation space easily, such as
door switch with escape function type.

5) Provide safety distance between fix guard and movable space of

robot 500 mm or more
6) Arrange monitoring person at outside of isolation space and that
position can look operation of robot safety. And Install emergency
stop button where the monitoring persons is stationed.

7) For push button which use for operate each axis of robot of teach
pendant, shall be push switch type that can feel when push it.

8) Install emergency stop button on teach pendant, and have function

which emergency stop all machine in isolation space.
Electrical Related
Measure Standard

<Refer TMS SEI2010n>

Content
● Basics of Electric Shock Prevention Measures
● Examples of Electric Shock Prevention
- Fixed equipment, control boards, and operation panels
- Portable electrical devices
- Arc welding equipment
● Supplement
On Electric Shocks
Electric shock accidents are
frequently caused by low-voltage
electricity.
* Low-voltage electricity refers to
600 V or less for Alternating Current
or 750 V or less for Direct Current.
When an electric current passes
through a human body, an electric
shock occurs.
* Range of voltage depend on each country government.

Electric shock hazards (of Alternating Currents)

Current Effect on human body
A few mA Senses stimulation (prickliness)
5 mA - 20 mA Painful shock (loss of coordination)
100 mA Myocardial spasm sometimes resulting in death

It becomes life-threatening if the product of current and time

is greater than 30 mAs.
 Electric shock hazards (of Alternating currents)
<100 V, but it can be highly dangerous, as shown below.>

Contact voltage
100 [V] x 100 [Ω]/110 [Ω] = 90 [V]
Transformer
Current passing through the body
Electric leak a. Under dry conditions
(Bodily resistance: approx. 3500 [Ω])
Current passing through human body:
90 [V] ÷ 3500 [Ω] = 25 [mA]
Class 2 Grounding
of machine
grounding b. Under wet conditions
Ground
(Bodily resistance: approx. 500 [Ω])
Current passing through body:
90 [V] ÷ 500 [Ω] = 180 [mA]

Chances of death
 Basics of Electric Shock Prevention Measures
(1) Use a machine that has no live part

(2) Protective grounding

Reduces the current passing through the human body by allowing
leaks, if any, to flow into the ground.

(3) Use of safety devices

- Ground-Fault Circuit Interrupter for shock
prevention (When a leak occurs in an electrical device,
this interrupter automatically detects it and breaks circuits.)

- Automatic voltage reducing device for

AC arc welding

(4) Use of double-insulated electrical devices

Examples of Electric Shock Prevention
(1) Fixed equipment, control boards, and operation panels
 The frame of an electrical device shall be grounded
(100 Ω at maximum).

 The live parts of an electrical device shall be placed under an

insulation cover or in an insulation box to prevent inadvertent
contact.
 Provide insulation covers for live parts in a board or panel.

 Connect the power wires directly to the primary side of the circuit
breaker. Avoid connecting power wires via a terminal board or the
like.
 The control board door shall be interlocked with the circuit breaker
so that the former will not open unless the latter is in the OFF
position.

 If some components require adjustments, it shall be possible to

adjust them from outside the board.
Examples of Electric Shock Prevention
4

Primary cable

Circuit breaker

Interlocked
door
Live
part
cover
5

Grounding Terminal block

Supplement ;
Interlock between disconnect switch and control unit
a) If the door of the control panel is a bi-parting door;

Circuit
Breaker

• It should be impossible to open door B with the power supply on.

• The circuit breaker should be equipped with a release function.
• It should be impossible to close door A and turn the power supply
on while door B open.
Supplement ;

b) Control panel consists of three or more panels;

• Open the main control panel door to turn the door switch off. This
turns the electromagnetic lock solenoid valve off and release the lock.
• It should be impossible to open doors B and C with the power supply on.
• If doors A and B of the control panel are bi-parting doors, the structure
must ensure the power cannot be turned on with door B open and door A
closed.
Examples of Electric Shock Prevention
(2) Portable electrical devices
 Use those equipped with a Ground-Fault Circuit Interrupter.

 Use electrical devices incorporating a double-insulation structure.

 Handheld lamps if used shall be with a guard.

 Use a plug incorporating a grounded twist lock.

(3) Arc welding equipment

 Use an insulation holder.

 Install an automatic voltage reducing device for AC arc welding.

 Ground the outer case of the welding equipment

and the secondary return wire.
Protective Grounding

<Refer IEC 60204-1, IEC 61537>

Content
● Requirements of the Protective Grounding
● Grounding Key Point
Requirement of the protective grounding

(a) The load side of control circuit are 24V DC and 110V AC shall be
connected to the protective grounding. (The minus side of control
circuit in DC)

(b) All the metal exposed section of the device where electrical device
is not applied current are connected to the protective grounding.

(c) Use copper wire for protective conductor.

(d) When bolts are being used on attaching surface where paint or
stains are removed, It’s considered as being connected to the
protective grounding.
(e) Devices attached through pendant, portable or cushion should be
connect with wire exclusive to the protective grounding.

(f) Don’t use race way and cable tray as protective grounding.

(g) Color of protective grounding wire are yellow and green stripes.

(h) The protective grounding size should not be smaller than specified
in table

* AWG (American Wire Gauge)

Grounding key point

(a) The device grounding resistance between the device metal section
and the protective grounding terminal shall be 0.1Ω or less.

(b) Protective grounding a single wire to a terminal, Do not connect two

or more wires to a terminal, nor connect wires indirectly.

<Protective grounding connection to terminal>

(c) Even if two or more control panels are connected by bolt, connect
between panels to protective grounding with conducting wire.
(d) If the protective grounding cable is exposed to foot traffic, use a
transparent vinyl tube or similar to protect it.

(e) If the terminal box for power circuit, motor of 25V AC or 60V DC or
more are wired by the connector anyway, protective grounding wire
between terminal box and M/C frame, it is different from protective
grounding wire in the connector.

<Protective grounding method of the motor and M/C main body>

<Protective grounding method in control panel> <Protective grounding method of the motor and terminal block>
 (f) When the wire is individually grounded, the protective grounding
shall be placed at a visible area.

<Example of grounding (separately installed equipment)> <Example of grounding (wiring duct)>

<Example Protective bonding method of connected control panel>

Safety Standards
for
Stairs and Ladders
<Refer TMS SQI0020n>
Content
● Measures against Persons Falling
- Stair construction
- Ladder construction
- Bridge structure
- Slope Way structure
Measures against Persons Falling.
Do not underestimate the height which you think is not “high”?

・ About 70% of accidents occur at a

<Ratio of accidents height of less than 5m.
according to height>

<Even less than 2 meter fatal accident could happen>

More than 5m
Less than 2m Example
30%
Eye bolt
36%
Bladder
More than 2m (For tyre injection)
Less than 5m

34%
Degree: Dead
1m
 Install a working floor
with a height of 2m or
Height/depth is more than 1m More.
⇒ Install the going up and down
equipment

Install handrail to prevent falling

Install a cover or lid, etc.

Install fixed going up and down equipment.

Measures against Persons Falling.

Going up and down the place that height

or depth is 1000mm or more must install
1m 1m
the going up and down equipment.
min. min.

Type of the going up and down equipment

a) The stairs
b) Ladders The going up and down equipment should
c) Bridge considering The stairs by prioritize.
d) Slope way
General Requirement
a) Hazardous objects such as bare electric wires or moving part of a
machine shall not be exposed within a 1000 mm area to the side of the
stairs.

b) No obstacles shall be present within the space of 2000 mm in height

from tread surfaces.
Stair Construction

≥100

≥600

≤100 ≤1200

≥2000
≥1100

200
≤ 1
≥100

≥900
 2
1

Item Specification
1)
1 Step Surface - Width : Approx. 230mm (Not less than 200mm)
(Tread) - Each step must be the same width
- Provide anti-slip measure on tread, If it’s likely to
slip.
2)
2 Height between step - General about 250mm (Not over than 300mm)
- Interval between step must same

Dimension
3 Slope Degree
Tread width Raising height
Recommend 47° 230mm 250mm
Max 56° 200mm 300mm
 ≥100
4
≥600 5.2 Baluster
≤1200
5
5.1
≥1100
ster
lu 0
Ba 120
≤ Tiptoe ≥100
5.3

≥900
5
5.1

Item Specification
4)
4 Stair width - Approx 600mm or more
5)
5 Hand rail 5.1 Height
: 900 mm or more on both side of the stairs
and 1100 mm or more on landing and base surface.

- Baluster
5.2 interval : 1200mm or less
-
5.3 Tiptoe board : 100 mm or more for landing or
platform.
 5.4 Gap of vertical bar ~120

Item Specification
5)
5 Handrail -
5.4Middle bar : 2 bar between upper bar and floor
surface by the same interval.
About handrail, it is possible if would use vertical bar
but in that case gap of vertical bar must around
120mm.
- In case of use handrail to be door type of slide type
must make strong structure that us lock pin for
open-close, etc.
 Fix part
6
≥100 mm

6 ≤100 mm

Item Specification
5)
6 Handrail clearance - Handrail to Handrail : 100mm or less
- Handrail to fixed part : 100mm or more
6)
7 Stair Landing - For stairs which height is over 10 m, must
set stairs landing within every 7.5m.
- At the side that not attach to wall, must
7.5 m.
10 m. install 1100mm up height handrail and
100mm up tiptoe board.
< Human height and handrail height >

To prevent persons from falling, the height of a handrail shall be

higher than the human center of gravity.

Standard height of
Center of male adult
gravity H = 1772 mm

Handrail height
1772 x 0.56 = 992 mm
Plus a margin, then,
1100 mm.

Stairs shall be provided with handrails 900 mm in height to be easy to

hold.
Ladder Construction
 2 Item Specification
1)
1 Tilt - Approx 5 degree from vertical

400-600
position
2)
2 Ladder width - 400 – 600mm
3)
3 Interval - equal interval 300mm
between Step (If there is fractional number of
step, possible to specify the
lowest step less than 300mm.)
- If ladder near the groove, can’t
install on the floor face. Step
distance from floor face : 600mm
≤600 300

3 or less
- Provide anti-slip measure on
1 step, If it’s likely to slip.
~5°
4)
4 Ladder Landing - If the height over 7.5 m must
install stairs landing at every 5 m.
- Must give priority to method to
change body direction when climb
up-down.
≤600

≥7.5 m
5m
 Item Specification
5.2
1100 mm 5)
5 Side rail -
5.1 The side rail be fixed at 300 mm
6
or less in height from floor face and
150-250 at 2500 mm interval or less
Upper floor
mm - Side rail extend 1100mm above
5.2
≤ 2500mm the upper floor face and be bent
5
5.1
toward the floor face.
- If make joint, side rail and side
5.3
5.3
rail, it must to put a round stick
inside and weld all surroundings.
≤ 2500mm

6
≥200mm

6)
6 Gap - 200 mm or more and at the top of
between rail work stand must have150 – 250mm
5.1 Side rail : ≤300mm and fix object
 Item Specification
7
7)
7 Safety - Provide a safety ring guard if

400-600
ring guard ladder is 5 m or more in height
(1) Start at 3 m from floor face
600-800 where forklift area.
mm
(2) Start at 2 m from floor face
where landing
- Diameter inside : 600 – 800mm

1000 mm 8)
8 Slide - Moving slide part must move as
guide lightly (3 kg or less)
- Moving slide part height from 2m
7 or less from floor surface
8
( Forklift area) (Slide part) - Be sure lockable when go up and
3000 mm
Height: ≤ 2000mm down
(Normal area) Weight: ≤ 3 kg.
2000 mm
Bridge structure
Structure that installed between machine
M/C M/C
and machine, meet item as following;

Item Specification
1) Width - Specify at more than 600mm.
- Even if there are obstacles, must keep gap
more than 400mm.
2) Handrail - Must install height 100mm. of tiptoe board at
height more than 1100mm handrail (both side)
but in case of have structure no need to keep
this condition.
- For other same as handrail stair
3) Strength - Considered about load at any position of floor
surface and another parts, no have dangerous
like broken down etc.
4) Material - Use steel to make structure, must make
structure that no slip, no stumbling
Slope way structure
Use in case of install slope way instead of stair
Item Specification
1) Incline degree - Less than 20 degree
2) Slip stopper - Take measure to prevent all slip at slope way
3) Floor material - Meet condition as strength of bridge
4) Handrail - Must install at both side
- For other same as handrail stair

Anti slip

<20 degree
 Setting Standards
of
Guarding cover
at connection of transfer conveyor
<Refer MMS SQI9035 n>
The covers should be mounted on the turning sections like
sprocket, tension and chain to prevent from being caught in them.
 Installation Standard

for Hoists using plain trolleys

<Refer MMS SQI9027 n>
Content
● Basic Concept
● Stopper
● Anti-Fall measures
- Hanger strut from auxiliary beam
- Preventing Bolts and Nuts from becoming loose
- Preventing the traveling part from falling off
Basic Concept
As the traveling hoist may fall off to impose a great possibility of danger :

a) An adequate safety factor (5 or more) should be used for

calculating strengths.

b) In addition to a construction that prevents slack caused due to

vibration and impact, an auxiliary safety measure such as
auxiliary wires should be used to prevent heavy objects from
falling off in case of slack.

c) A construction that permits daily inspection of the components

related with the fall should be used and an inspection means
(inspection platform) provided.

d) This standard defines the guideline for securing hanging

equipment safety. Consider the standard and regulations of
each country for installation
Stopper
Stoppers at the ends of travel

a) The stoppers should be of a double construction (A cushion should

be provided at the trolley contact surface.)

b) The stoppers should be installed parallel.

c) Stopper bolts installation should be prevented from becoming loose.

d) The stoppers should be protected from impact loads.

e) The stopper and stopper bolt installation strengths should have a

sufficient margin.
Stopper
Anti-Fall Measures
1) Hanger Strut from Auxiliary Beam
2) Preventing Bolts and Nuts from becoming loose.
Selection criteria for bolts and nuts:
Consider the presence of vibration and other conditions of use

Part subject to excessive impact/vibration Ordinary portion (prevented from

(prevented from losing axial force) losing axial force)

Ordinary portion Parts subject to excessive impact/vibration

(prevented from reversing) (prevented from losing axial force)

Tightening structure of bolts and nuts (example)

3) Preventing the traveling part from falling off
Anti-fall stopper is A provision (anti-fall stoppers, etc.) is required to
prevent the hoist from falling off. Wires should be used absolutely
necessary.
a) Synchronized carrier;
- When hoisting a plant or such with the trolley, apply wires.
(Select wires with a diameter not less than 6 mm that match the
weight of the plant to be hoisted.)
- The bracket should be of a lock nut type (with paint marks)
- Visually check the welding strength (penetration).
- Install the wires with some slack in them.
* If they are as tight as the major hardware, the hardware
may be continuously used with its failure not noticed until either
wire is broken.
 In case of can’t use lock nut type,
It’s require full welding line at joint portion

Preventive measure against fall of synchronized carrier (Example)

b) Balancer
- Install wires with some slack in them. If they are as tight as the
major hardware, the hardware may be continuously used with its
failure not noticed until either wire is broken.
4) Auxiliary wires and clips
For auxiliary wire types, see JIS G 3537:1994,JIS G 3201:1998,
JIS G 3525:2006.
a) - For wire clips and wire ropes for auxiliary wire, use the FR8 or
MR8 specification by JIS B 2809:1996 (wire ropes – Grips for
rope or wire strand) equivalent.
- For auxiliary wires, use wire ropes (R) with an OD of 6.3mm
(FR8) or 8 mm (MR8) specified by JIS G 3525:2006 or
equivalent
b) Incorrect Installation of wire clips may reduce the
withstanding load to a half. To install them as
shown below (Not concentrate the stress, the
surface contact side should be used for hanging)
c) For auxiliary wires only, two or more clips are to be used.
Tightening torques are shown in table (9.5)

d) After installed wire clips, tense the rope to eliminate slack and
then tighten the clips.

e) The wire clip nuts should be of a double type or prevented from

becoming loose.

c) When wires are used, a provision is required not to make the

radius of curvature too small (to prevent the wires from being
cut off)
 Number of clips. Tightening torques when used as a main wire
Refer to table below, for clip numbers and tightening torques if the wire
is to be used as a main wire (constant regulated load).

Table
(berlaku)

(Penilaian risiko)
 Shop Machine Layout

5 6 7 9
29 71 13
70 16 10 14 28
69 12 15
30 1 3 2 4 8 11 19
17 18 20
72 73
21
68 67 74 26

31 25 22
66 24
27 23
76 75

33 32
77
62 60
61
59
35 34
63 64
36
78
65 79
41 42 43
37 38 53

46 39
48 80 81
47 45
40
49
44 92
50 51
82
58 52
57 54 89 87
86
56 93 88 104
55 98
90 99 103
94
95 84
9685
97 91 102
100 101
105
83
 Department : Assembly Shop
Machine / Equipment Master List Total No of Machine/Equipment : 105

Japan Sourced Equipment

Section Line No Register No. Equipment Name Existing Safety Device E-STOP Driven By
Equipment Vendor

L1 Line

L1 Final 1 A-L1F-001 L1 Conveyor No sensor for open fence Yes NKC Pnuematic + Electric

L1 Final 2 A-L1F-002 P/S,LLC,W/W Filling Machine LOTO, E-STOP, Safety Plug IDEC Yes Decker Pnuematic + Electric

L1 Final 3 A-L1F-003 Portable air cond machine Stop Button No Robina Electric

L1 Final 4 A-L1F-004 Petrol & diesel pump E-STOP, Auto cut off, E-Valve Yes Tatsuno Electric

L1 Final 5 A-L1F-005 Primer Shaker machine Safety Guard fence No Local Pneumatic

L1 Final 6 A-L1F-006 Brake bleeding machine LOTO, E-STOP, Safety Plug IDEC Yes Decker Pnuematic + Electric

L1 Final 7 A-L1F-007 Graco sealer pump Not applicable Yes Graco Pneumatic

L1 Final 8 A-L1F-008 Punch Plate Numbering machine Not applicable No Technifor Pnuematic + Electric

L1 Chassis 9 A-L1C-001 Tye Lifter (RHS) LOTO (AIR), Tyre lifter cover No Local Pneumatic

L1 Chassis 10 A-L1C-002 Scissor Hanger CH 2 No Double Stopper Yes Demag Electric

L1 Chassis 11 A-L1C-003 Tye Lifter (LHS) LOTO (AIR), Tyre lifter cover No Local Pneumatic

L1 Chassis 12 A-L1C-004 Knuckle Hoist Wire Rope balancer, Double Stopper Yes Demag Electric

L1 Chassis 13 A-L1C-005 Transmission Hoist Wire Rope balancer, Double Stopper Yes Demag Electric

L1 Chassis 14 A-L1C-006 U-Bolt Nutrunner (Uryu) Wire Rope balancer, Double Stopper Yes Uryu Pneumatic

L1 Chassis 15 A-L1C-007 RR Axle Hoist Wire Rope balancer, Double Stopper Yes Demag Pneumatic

L1 Chassis 16 A-L1C-008 Transverser Lifter c/w Scissor Lifter E-STOP IDEC No Local Pneumatic

L1 Chassis 17 A-L1C-009 Scissor Hanger CH 1 No Double Stopper Yes Demag Electric

L1 Chassis 18 A-L1C-010 RR Lifter Balancer Not applicable Yes Endo Pneumatic

L1 Trim 19 A-L1T-001 I/P Manipulator Wire Rope, LOTO (AIR) No Proviesys Solution Pneumatic

L1 Trim 20 A-L1T-002 Door Less Manipulator LOTO (AIR) No Local Pneumatic

L1 Trim 21 A-L1T-003 Sliding Door Manipulator LOTO (AIR) No Proviesys Solution Pneumatic
Risk Assessment Sheet
 Summary Risk Hazard
LOSS of STABILITY
SLIP,TRIP AND FALL OF
MECHANICAL HAZARDS ELECTRICAL HAZARDS THERMAL HAZARDS NOISE VIBRATIONS RADIATIONS MATERIAL/SUBSTANCES ERGONOMICS FALLING OR EJECTED OVERTURNING OTHERS
PERSONS)
MACHINERY

TMAP-
ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB TMAP-EM ASSB
LINE EM

Risk 5

L1 LINE
Risk 4

Risk 3

Risk 5

L2 LINE
Risk 4

Risk 3

Risk 5

L3 LINE
Risk 4

Risk 3

Risk 5

ABS
Risk 4

Risk 3

Risk 5

Total Risk 4

Risk 3

Total

Total Hazard
 Action & C/measure Plan
Oc t 1 1 No v 1 1 De c 1 1 Jan 1 2 Fe b 1 2 M ac 1 2

Wk 1 Wk 2 Wk 3 Wk 4 Wk 1 Wk 2 Wk 3 Wk 4 Wk 1 Wk 2 Wk 3 Wk 4 Wk 1 Wk 2 Wk 3 Wk 4 Wk 1 Wk 2 Wk 3 Wk 4 Wk 1 Wk 2 Wk 3 Wk 4

Study
Procurement
Plan

Fabricate & Installation

Check
Complete
Study
Procurement
Actual

Fabricate & Installation

Check
Complete
Study
Procurement
Plan

Fabricate & Installation

Check
Complete
Study
Procurement
Actual

Fabricate & Installation

Check
Complete
Study
Procurement
Plan

Fabricate & Installation

Check
Complete
Study
Procurement
Actual

Fabricate & Installation

Check
Complete
Study
Procurement
Plan

Fabricate & Installation

Check
Complete
Study
Procurement
Actual

Fabricate & Installation

Check
Complete
(Penilaian risiko)
 (Menentukan tahap/had sesebuah mesin)

(Sekatan mengenai ruang pemasangan mesin)

(Penggunaan & Penyalahgunaan mesin yang diramalkan)

(Orang yang dijangka menggunakan mesin ini, keupayaan fizikal, pengalaman & tahap latihan yang diperlukan
untuk operasi)

(Kemungkinan orang yang terdedah kepada bahaya disebabkan oleh mesin)

(sebarang kemalangan yang melibatkan sesuatu proses/kerja)
(Bahan Berbahaya)
(Menganggarkan)
(Keterukkan Bahaya)
(Kekerapan & Tempoh)

(Kemungkinan utk
mengelakkan)
(Kebarangkalian Bahaya)

(terdedah)

(Ketidakupayaan yang tinggi/teruk)

(Ketidakupayaan yang kecil)

(Hanya rawatan First Aid)

(semasa masa operasi)

(semasa low frequency)

(Kemungkinan utk mengelakkan)

(Ditentukan kemungkinan orang yang terdedah

kepada bahaya boleh mengelakkan dirinya dari
kemalangan/kemudaratan)

(Mustahil) (Tidak dapat dielakkan)

(Mungkin) (Boleh dielakkan)

(Kebarangkalian Bahaya)

(Kebarangkalian boleh dikurangkan dengan mengambil langkah perlindungan

yang sesuai

(Keadaan berbahaya kerap terjadi)

(Keadaan sesuatu tempat tiada
(Sangat Bergantung) langkah perlindungan)

(Ada kemungkinan bahaya)

(Langkah perlindungan tidak mencukupi)

(Kecekapan mesin yang tinggi)

(Terdapat langkah perlindungan & mengikut piawaian

(Sangat bergantung kepada langkah perlindungan pada kawalan kejuruteraan

(Dari pusat
(tajam)
keatas)
(Tiada pengasingan)
Examination Test