Category 4 Press Line safety upgrade

The challenge: designing and integrating Category 4 compliant safety upgrades to existing press lines, combining individual manual presses with a series of automated presses (including press tending robots).

ICT responded to this complex brief with a methodical and structured development approach, firmly underpinned with ICT's Quality System. This left no room for error and ensured every design opportunity (and difficulty) was identified, evaluated and addressed.

The initial step was a comprehensive on-site Hazard Analysis and Risk Assessment to determine risk control requirements and accumulate a thorough understanding of the existing system.

ICT's subsequent quality-assured design process helped ensure that the solution was in accordance with the stringent requirements for Category 4 under AS 4024.1 Safety of Machinery. The detailed designs were subject to an Independent Design Review – a design step prescribed for every project by ICT's Quality System. The review process identified areas for amendment, setting fixed actions for remediation, and subject to those amendments confirmed the design met customer and regulatory requirements. It also introduced fresh eyes, experiences and thinking to the design process. Such review is in accordance with the requirements of AS 61508 for safety related control system implementation.

The solution involved a combination of components from a variety of suppliers including Pilz (PSS), Siemens and Sick.). ICT developed detailed commissioning procedures and supervised the electrical installation – all undertaken in a tightly-planned shut-down window.

The ICT deliverables included maintenance manuals, operator's manuals and CAD schematics in addition to operator and maintenance training. ICT contributed over 1400 man hours over a 5-month period to this project, resulting in a safe, fully-compliant production line, which has earned excellent customer feedback and follow up projects.