Page 10 - OHS, April 2020

FACILITY SAFETY
breadth of most industrial facilities. Akin to smart home systems that control temperature, lights, appliances and doors, IIoT systems in industrial workplaces can connect plant exteriors and loading docks to plant interiors and freezer/cooler areas—thereby collect- ing and dissecting safety data on a facility-wide scale rather than individual workers or locations.
Forklift interactions are particularly dangerous. Consider that, according to Optimum Safety Management,3 in the U.S. alone:
■ Nearly 100,000 workers are injured per year due to forklifts;
■ Approximately 85 workers die due to forklift accidents each year; and
■ More than one in 10 forklifts will be in an accident every year (855,900 forklifts in U.S. and 97,000 annual forklift injuries).
Connecting IIoT systems with various pieces of smart equip- ment can pinpoint areas of risk at a plant like isolating potentially dangerous work areas to noting the highest traffic times of day. Capturing and centralizing this information is the first step in un- derstanding the picture in any facility.
Not All Data is Useful
One common challenge facing facilities bringing IIoT systems on line is the sheer volume of data they collect. Simply put, it can be overwhelming, making it difficult to distinguish what information is useful and identify trends or opportunities for improvement.
The best practice is an IIoT system that not only harvests raw data, but also allows the customer to drill into the details and pro- vide users actionable insights so they can make data-driven deci- sions. The users of this IIoT data can identify specific trends, like what’s causing increased energy loss, why productivity is decreas- ing or areas that are creating the potential for unsafe events. It al- lows facility managers to “see” what they’re missing.
Improving Facility Safety through the IIoT
Smart equipment is the first step. Through advanced controls and sen- sors, simple machinery like high-speed doors and vehicle restraints can now capture events that can be reviewed through a centralized dashboard if connected through IoT. At their most basic, IIoT sys- tems can send real-time safety alerts when something is wrong. The next level of advancement would include trending alerts that can warn facility managers if broader urgent actions are necessary.
The top-tier IIoT systems do even more. By examining the data, they can help facility managers gather insights they might not have drawn otherwise. By correlating current data points with histori- cal trends, these systems can help identify corrective actions to im- prove specific safety points and safety behaviors—a much more en- lightened approach than simply making changes after an accident or relying on employees to report a “near-miss.”
Leading IIoT systems allow safety personnel and plant manag- ers to identify potentially unsafe events. As an added benefit, they may also discover new equipment or maintenance needs, potential training opportunities and process improvements.
Specific Areas for Implementation
Let’s take a look at some specific operational areas that can be en- hanced by IIoT-informed management.
Loading dock equipment that is interlocked and allows proper sequence of operation is enhanced when controls are smart and connected to an IIoT platform. Here are a few control examples:
■ Vehicle restraints: An employee may attempt to operate the leveler without engaging the restraint. The event will be logged, and the safety contact can receive an alert.
■ Dock door barrier: Identify a potentially unsafe event when the dock door is left open with no trailer present and the barrier is not engaged.
■ Motion sensors and light communication: When there is activity in the trailer, a blue light emits and prevents the vehicle re- straint from erroneously unlocking the trailer when activity inside is detected.
Safety managers can use this data to see near misses that might have otherwise gone unnoticed or not been reported. An electronic tool like IIoT can document these instances without the human element of turning in a co-worker. They will stay up to date on changing employee behavior that might be dangerous, as well.
Inside the plant, workflow can be monitored to understand higher risk areas and even when an increased risk is likelier to occur. This can provide vital information to facility managers to not only improve safety but also increase productivity, as workers can be more certain of their own movements. Here are a few areas where technology can tap into the power of the IIoT:
■ Dangerous intersections: Intersection warning systems can increase safety through intuitive communication. Data can be pro- vided to determine directional interaction and assist with next steps.
■ High-speed door openings: Communicate when a door has been left open, which can cause moisture buildup and lead to an unsafe condition.
Combining multiple data points and reviewing diagnostic ana- lytics with IIoT technology allows companies to improve safety.
The IIoT Future is Already Here
A safety revolution is coming by the way of interconnected devices. Whether it’s at the loading dock or inside the plant, facilities that have already invested in IIoT are seeing the safety benefits. Ac- cording to a PwC survey published in Industry Week, 93 percent of manufacturers believe IoT benefits exceed any risks.4 Addition- ally, the survey revealed that approximately 70 percent of industrial manufacturers plan to increase their investment into IoT within the next two years. Companies that aren’t using IoT to improve the safety in their manufacturing plants in the very near future are at risk of falling behind the competition.
Now is the time to begin investing in IIoT technology that can protect your organization’s most precious asset: your workers.
Tim Kubly has more than 14 years in the materials handling indus- try, including eight years with Rite-Hite. As the business development manager for Rite-Hite Digital Solutions, Kubly leads the initiative to provide solutions through dock and trailer management software.
REFERENCES
1. https://www.nsc.org/Portals/0/Documents/JSEWorkplaceDocuments/ Infographic-injuries-bythe-Numbers.pdf?ver=2019-04-17-182214-630
2. https://injuryfacts.nsc.org/work/costs/work-injury-costs/
3. https://www.optimumsafetymanagement.com/blog/forklift-safety-
infographic/
4. https://www.industryweek.com/technology-and-iiot/ article/22028667/2020-future-of-manufacturing-technology
10 Occupational Health & Safety | APRIL 2020
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