GSS-M

GSS-M

Machine Operations Safety Guide part

Form 1 GSR-0Z-001
Page 1/2

Class Sumitomo Riko Safety Standard Classification㻌 No. GSM䠉00䠉005-

Name Machine Operations Safety Standard㻌 Established Date: 01/04/2015
Last Revised Date: 01/04/2015

1. (Objective)
This Standard provides for procedures to ensure safety after the introduction of machinery in
order to prevent industrial accidents or hazardous events while machinery is running at
Sumitomo Riko or its subsidiaries.

2. (Scope of Application)
This Standard shall be applied to Sumitomo Riko and all its subsidiaries.

3. (Definition)
(1) Base: Business places, plants and workplaces of Sumitomo Riko and its subsidiaries
(2) CSR Safety and Health Committee: One of the sub-committees of Sumitomo Riko CSR
Committee, under which there are working groups such as Machine Safety, Fire Prevention
and Work Safety.

4. (Applicable cases)
(1) Industrial accidents covered by this Standard shall be injury and sickness.
(2) Hazardous events covered by this Standard shall include fire, explosion, leakage of electricity
or harmful substances such as gas and liquid, and scattering of dust and fine particles.
(3) This Standard shall not be applicable to natural disasters such as earthquake and wind and
flood damages.

5. (Compliance)
Each section is required to comply with any and all national or local laws and regulations applied
at its location (“applicable laws and regulations”).

6. (Operation Safety)
(1) Operation safety is the activity to maintain and operate machines in such a way as to prevent
accidents or hazardous events arising from the machines, that is, maintenance work as
follows:
ձ Manufacturing Section and Maintenance Engineering Section shall carry out maintenance
per schedule specific to each machine.
ղ Manufacturing Section and Maintenance Engineering Section shall promptly carry out
repair if faults such as damage and deterioration are found.
(2) Maintenance activities for operation safety are divided into the following:
daily inspection, regular inspection, regular maintenance, legal inspection, legal examination,
regular self-examination

7. (How to Handle Machine-related Accidents/Events)
(1) If any industrial accident or hazardous event occurs in relation to machinery, the Manufacturing
Section shall immediately report to Safety & Health Section at each base, which then report to
the Sumitomo Riko Safety and Health Department on the situation where such accident or
event occurred.
(2) Related sections shall work together to identify the cause to immediately determine and
implement preventive measures.
(3) The Manufacturing Section shall notify determined preventive measures and its completion
date to the Safety and Health Section at each base, which then report to Sumitomo Riko’s
Safety and Health Department.

Drafted by Approved by Person responsible
Yoshinobu Isobe
Chairperson of Machine Safety WG General Manager of Safety & Health Chairperson of CSR Safety & Health
Dept. Committee

Hiroshi Nouso Ken Kono Rikizo Tatsuta

Classification No. 㻳㻿㻹㻙㻜㻜㻙㻜㻜㻡 Form 1 GSR-0Z-001
Page 2/2

8. (Horizontal Deployment of Machine-related Accident & Event Information)
Machine Safety, Fire Prevention and Work Safety Working Groups and Sumitomo Riko’s Safety
and Health Department shall decide, as necessary, to implement inspection and
countermeasures for other machines similar to the one having caused the accident or hazardous
event.
(1) The Sumitomo Riko Safety and Health Department shall instruct each base to implement
inspection and measures as determined above.
(2) The Safety & Health, Equipment Engineering, Production Engineering and Maintenance
Engineering Sections at each base shall work together and promptly carry out inspection
and measures against faults as instructed.
(3) The Safety & Health Section at each base shall present the result of above mentioned
inspection or measures to Sumitomo Riko Safety & Health Department by a designated
date.

9. (Machine Repair needing Notification to Competent Authorities)
If damages and deteriorations leading to accidents/hazardous events are identified through
operation safety activities and machines need repairing, the Maintenance Engineering Section
and the Equipment Engineering Section shall consider the necessity of making application,
notification or report for such repair to competent authorities (“application”), and carry out the
following as required.
(1) The Maintenance Engineering Section shall notify the Safety & Health Section of such fact.
(2) The Safety & Health Section shall prepare statutory documents required for such application.
(3) The Safety & Health Section shall make an application to a competent authority by the legally
designated date.
(4) The Maintenance Engineering Section shall conduct repair to the extent applied for it after the
date of permit or acceptance by the applicable authority.
(5) If it is found that repair beyond the extent permitted or accepted by a competent authority
might be necessary just before, during or after repair, the Maintenance Engineering Section
shall immediately stop applicable repair work and notify the Equipment Engineering Section
and the Safety & Health Section to ask for instruction. The Safety & Health Section shall
consult with a competent authority and file an application again.
(6) Upon completion of repair, the Maintenance Engineering Section shall notify the Safety &
Health Section.
If the post-repair inspection by a competent authority is required by statute, the Safety & Health
Section shall arrange the date for such inspection.

10. (Disposal of Machine)
In disposing of machinery, the Equipment Engineering Section shall return the installation site to
such state as it was in before installation in terms of safety/health and the environment as much
as possible. The Equipment Engineering Section shall investigate the necessity to apply for such
disposal to a competent authority, and execute the following as necessary.
(1) The Equipment Engineering Section shall notify the Safety & Health Section of the necessity
of application.
(2) The Safety & Health Section shall prepare statutory documents required for such application.
(3) The Safety & Health Section shall make an application to a competent authority by the legally
designated date.
(4) The Maintenance Engineering Section shall dispose of machine only to the extend applied for
it after the date of permit or acceptance by an applicable authority.

(Supplemental Provisions)
1. This Standard shall be maintained by Sumitomo Riko’s Safety and Health Department.
2. This Standard shall go into force on April 1, 2015.
3. Concrete operation of the provisions herein shall comply with the Machine Safety Operation Guide
(Classification No.: GSM-0G GSS-M).

Machine Operational Safety Sumitomo Riko Group

Promote machine operational safety to prevent industrial accidents and other
incidents caused by the machine

Operational safety refers to:
activities to operate, maintain and manage the machine so as to prevent the machine
from causing accidents and incidents.

【Accidents and Incidents in the Scope of Operational Safety】

(1) Accidents
●Injuries and illnesses

(1) Incidents
●Fire and explosion
●Leakage of electricity and gaseous/liquid hazardous substances
●Scattering of fine particles and powder

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Machine Operational Safety Sumitomo Riko Group

Machine operational safety is required for the following machines in order to
prevent industrial accidents and other incidents.

(1) Machines similar to a machine that has caused an accident or incident in the past
(electrical machines, exhaust ducts, etc.)

(2) Machines that require statutory inspection (pressure containers, cranes, elevators,
etc.)

(3) Safety devices (for safeguarding or additional protection)
(4) Machines that use hazardous substances (from supply to discharge process)
(5) Machines that use or generate harmful substances (toxic and hazardous substances)

(from supply to discharge process)
(6) Machines that use or generate fine particles or powders (from supply to discharge

process)
(7) Machines that use gas (from supply to discharge process)
(8) Machines that may cause a steam explosion

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Machine Operational Safety Sumitomo Riko Group

The following items shall be implemented to prevent industrial accidents and
incidents caused by machine operations.

Daily Inspections: Daily inspections, cleaning and oil Regular Inspections and Regular Maintenance
refilling that are carried out to check whether or not
there is any abnormality in the machine based on the Machine inspections, audits and repairs carried out
process control standard or the daily inspection by technical engineers based on specific timelines
checksheet, using five senses or inspection equipment. according to the Machine Maintenance Plan.

Frequency: At start of shift, daily, weekly and monthly. Frequency: Monthly, every 3 months, annually and
every several years
Responsible Sections: Sections using the machine Responsible Sections: Maintenance Engineering
Section

Statutory Inspections and Statutory Audits

Regular voluntary audits, etc. : Inspections or audits that are required by law to maintain the performance
Frequency of the machine

: Frequency stipulated by

Responsible Sections : Sections using the machine, Maintenance Engineering Section and persons
designated according to relevant laws, regulations and standards in a
country or region in which the machine is located (a statutory operation
manager, for example)

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Machine Operational Safety Sumitomo Riko Group

Response Flow: When accident or incident caused by the machine occurs

Section using the Collaboration
machine

Make sure to report the Report the Find the root causes Safety and Health
accident or the incident that accident Section
has occurred without fail Decide recurrence
prevention measures Equipment
Engineering
Section, Production
Engineering Section
and Maintenance
Engineering Section
at the site

Safety and Health Section
at the site

Report the Decide recurrence
accident prevention measures

implementation deadline

Safety and Heath Section
at Sumitomo Riko

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Machine Operational Safety Sumitomo Riko Group

Response Flow: Horizontal deployment of measures for accidents and incidents
caused by the machine

Sumitomo Riko Safety and Health Section

Horizontal Deployment of Measures Reliably prevent
Consultation recurrence of accidents
and incidents through
CSR Safety and Health Committee Groups horizontal deployment
Equipment Safety, Work Safety and Fire Prevention of the measures

Equipment Horizontal Deployment Items Section Using the machine
Engineering Section Proposals Production Engineering
Section
Sumitomo Riko  Maintenance Engineering
Safety and Health Section Section

Horizontal Deployment Items
Instructions

Collaboration

Inspection Safety and Health Inspection
Measures Section at the Site Measures

Report Results

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Machine Operational Safety Sumitomo Riko Group

Response Flow: Machine repairs that require a notification to the government
agencies

Collaboration When an implementation item that is beyond
the scope of the repair plan approved or
Engineering Maintenance Maintenance authorized by the government agency arises or
Equipment Section Engineering Section Engineering Section is expected to arise.

N/A Statutory Start
investigation repair

Start Applicable
repairs
Reporting
Submit necessary documents Contingency Yes
No
Safety and Health Section Reporting
at the site Submit necessary documents Damage or deterioration
found in operational safety
Application / Notification / Reporting Safety and Health Section activities which may result in
at the site an accident or an incident =>
Repair
Consultation
Application / Notification / Reporting  => Make sure to receive
approval or authorization
Responsible government agency Responsible government  from government agency
Approval / Authorization agency  without fail.

Complete
Repair

Safety and Health Section  Safety and Health Section Audit by the
at the site at the site agency

Report approval of repair Report Responsible 
completion government agency 

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Lateral deployment of accident information SUMITOMO RIKO Group

No. Date of Machine name Accident conditions Items to be investigated by the entire group
09-02s-1 accident
・Safety door
09-02s-2 11/04 Dynamic spring Machine did not stop till the cycle was completed even if the 1. Machine stops on opening the door.
/2008 test safety door was opened, and the associate had their hand 2. Door won't open until the machine stops.
09-02s-3 pinched. 3. After door opening/closing, the machine will be activated by pressing the
reset button.
12/02 Fluorine resin The associate tried to clean the sensor inserting their hand ・Cover is not left removed or broken.
coating machine through the clearance made by removing the cover and had ・Parts of the body that might be inserted won't come in contact with the
/2008 the hand pinched between the moving parts. moving parts.

12/25 LIM molding The associate tried to clean the machine inserting the hand
/2008 machine through the fracture of the cover and had the hand pinched
between the moving parts.

09-03s 01/07 Assembly-in- Jig change-over cart stuck when pulled out and jig fell down ・Jig change-over cart is not broken.

/2009 liquid machine on the associate's hand. ・Work is not conducted under unstable conditions.

09-04s 10/21 Sheet shutter Shutter sensor did not work and the associate was hit by the ・Opening/closing sensor, obstacle detecting sensor and shutter up switch
/2008 descending shutter. are installed.
・There is a sign to urge personnel to walk the button-installed side of
pathway.

09-05s 02/17 Urethane In removing burrs in the machine with the safety door ・Presence of machine whose safety door is currently deactivated.
/2009 stopper line deactivated during trial operation, the associate had the hand ・Presence of machine whose safety door was previously deactivated.
pinched by a part that abruptly began to move.

09-07s 04/24 Water purifier The inspector left the site with the man-hole lid removed, and Contractors attend the safety education session as instructed.
09-11s /2009 tank a passer-by tripped on it and fell down.
09-15s
・Safety device is installed at the injection cylinder cleaning location.
09-12s
2009/ The associate cleaning the injection cylinder had their hand
09-16s 09/09 Curing machine pinched because another person descended it without giving Work procedures include the instructions to:
・Switch from AUTO to MANUAL;
a signal.
・Switch off the operation ready; and

・Post an out-of-service sign on the control panel.

The associate inserted the finger through the grease inlet port ・Similar machines cover the portion through which finger may reach the
to check the temperature and had the finger cut by the
09/16 TSC rotating part inside the cover. moving parts.
/2009 spiral machine ・Post a sign to discourage finger insertion.
・KY inspection

10/21 A/C hose While using the crane whose over-wind prevention device is ・Pre-operation inspection is conducted for the over-wind prevention
/2009 Curing machine out of order, wire broke and the load dropped.
crane device.
・Hoisting allowance for usual operation is investigated.
・Regular check is conducted.
・Compliance to overseas local statutes is confirmed.

10-01s 04/01 1-S/RL In shift work which started without the morning meeting as the ・Check for cases of the absence of a supervisor (unit leader), and take
/2010 unit leader was absent, the associate wound the roll without measures against such abscences
wearing protective gloves and had their hand cut with a knife. ・Checking means and established system to ensure use of protective
gloves. They must be improved so that anyone can follow them if necessary.

10-02s 04/06 Material When moving backward after placing the pail can in storage Personnel may bump their heads on Storage units, warehouses and shelves
10-03s /2010 storage with a low ceiling, the associate bumped their head on the - Take measures against this if necessary.
10-04s ceiling and had it injured.
04/19
/2010 Cafeteria door Moving out of the cafeteria, the associate was hit by the door ・Presence of door without awindow.
opened from the opposite side. ・Post a notification sign.
04/27 ・Installation of a viewing window
/2010
TSC The associate tried to remove foreign material from the take- ・Location of take-off machines.
off machine roller. ・Check if hands and fingers can reach the caterpillar.
・Take countermeasures if hands and fingers can reach it.

10-05s 2010/ Surface The associate had the hand injured by a grinding stone still ・Application of surface grinders, bench grinders and high speed cutters
06/18 grinding rotating with inertia even after having been turned off. ・Installation of the lamp to indicate the grinding stone is rotating
machine ・Alternative means to indicate the rotation of the grinding stone when the

indicator lamp is not present

11-01s 04/20 Rotary curing The associate had the hand pinched by the die while ・Moving parts within person's reach stop immediately when the safety door
/2011 machine checking residual runner with the safety door open.
is opened.
・Breaking a laser beam immediately stops the machine.
・Activation of emergency stop functions such as the emergency stop button

immediately stops the machine.
・Servo mechanism is turned OFF in entering robot motion range.
・Work whose procedures are not established and anticipated accidents

12-01s 09/03 Hand lift In unloading the drum can from the hand lift manually rotating ・Necessity of drum transferring operation
/2012 it, the groin got hurt. ・Contents and manner of drum transferring operation
・Necessity to swing drums
・Required number of personnel and frequency

14-01s 07/24 Press The associate reached for the closing die to correct it, ・Two-handed operated switch and safety light curtain are installed as per
/2013
breaking the area sensor beam, but had the finger pinched. the standards.

Lateral deployment of fire accident information SUMITOMO RIKO Group

No. Date of Machine name Accident conditions Items to be investigated by the entire group
accident
・Installation of the device to prevent excessive temperature rise
09-01k 12/18 Secondary Oil on the furnace wall caught fire due to excessive ・Setting of the device to prevent excessive temperature rise
/2008 curing machine temperature rise caused by broken heater fan belt ・Operation of the device to prevent excessive temperature rise
・Fan driving system
・Fool proof measures in case of belt breakage
・Maintenance of regular cleaning/inspection record

09-08k 06/15 Air compressor A malfunctioning motor caught fire, which expanded to ・Implementation of regular inspection and servicing of the compressor
/2009 surrounding soundproof material ・Presence of surrounding flammables (e.g. soundproof material

impregnated in oil)
・Maintenance of regular cleaning/inspection record

09-09k-1 07/23 LLTI Heater lead shorted out due to abraded coating and a spark
/2009 ignited the rubber burrs accumulated around it.
・Breakage of heater lead coating
09-09k-2 08/24 Press Press band heater wire shorted out due to coating thermal ・Check for and clearing of surrounding rubber burrs and other flammables
/2009 degradation and ignited material adhered around the wire.

09-10k 09/02 Bucket Transformer CP capacity was too large to detect overload ・CP or fuse is installed on the control transformer
/2009 conveyor and transformer coil was heated and caught fire. ・CP or fuse capacity is proper.

09-14k 11/02 Die preheating Removed heater was hung on the machine without turning off ・Heater installation/removal procedures are established for the machine
/2009 chamber the power and overheated to ignite the control panel plastics
with the cartridge heater.
・Mechanism to prevent heating the empty chamber is employed.

10-01k 10/06 Electric water Heating without water occurred in the water heater due to ・Presence of electric water heater
10-02k /2010 heater absence of the device to prevent it, and ignited the thermal ・Installation of device to prevent heating without water
10-03k insulating cover.
10/14 Vacuum pump Hazardous substance temporarily absorbed and filtered in a Hazardous substances with the 40℃ or lower flashing point and location of
10-04k-1 /2010 non-explosion proof area exploded due to sparks generated their usage
10-04k-2 Hose drying when the pump was activated.
11-01k 12/23 furnace ・Possibility that work may enter the furnace through the clearance and
/2010 Hose product dropped through the rack clearance, came in touch the heater
contact with the heater and ignited. ・Countermeasures and delivery date rescheduling in case of fault

03/08 Welding Spatters generated during ordinary operation ignited the dust ・Spark generating machine has proper spatter prevention measures.
/2011 machine
accumulated on the back of machine and ignited the power ・Spark spattering range is regularly cleaned to remove flammables.

cable coating. ・Welding fume discharging duct is not laid where it may suck in flying

04/04 Welding Spatters were sucked into the fume discharging duct and spatters.
/2011 machine ignited accumulated dust. ・Countermeasures and delivery date rescheduling in case of fault

06/17 Curing can Oil or cleaner having soaked into the heat insulating material ・Structure prevents oil or organic substances from adhering to or soaking
/2011 was oxidized and heated to generate smoke.
into heat insulating material.
・Heat insulating material has not absorbed oil.

11-02k 06/20 Dirt on the electrode connection with the clip caused fault in ・Presence of machines, devices and jigs that use clips to connect live
/2011 Die cleaning conductivity, resulting in current reduction. Seeing this, the parts.
electrolytic bath associate raised the current setting, which made the

connection overheat and the clip caught fire.

12-01k 07/03 Charging roll ・The machine is provided with fool-proof mechanism to stop high-voltage
/2012 tester
Defect of product to be evaluated caused electric discharge power sources under abnormally high voltage.
between electrode and electric roll, and resin member on ・The machine is provided with fool-proof mechanism to detect leak

which large amount of conductive grease was applied caught (electric discharge) and stop high voltage generation.
fire. ・There are no flammables around electrodes or devices.

・Cleaning record and presence of anomalies (dust/ contamination)

11/06 Where there is wiring cover fracture, wire coating was peeled ・Check for heater lead and wiring cover for damages.
/2012
12-02k Curing machine and a short-circuit occurred. Generated sparks ignited rubber ・Adhesion/accumulation of rubber burrs, dust and dirt.

burr adhered on the wire. ・Implementation of regular inspection

Control panel was cleaned with cleaning agent to remove oil ・Control panel cleaning manner
・Flammable spray use and its application for machines that may generate
13-01k 07/12 Curing machine contamination. The agent volatilized and filled the panel with
/2013 flammable gas. The gas caught fire and exploded due to sparks

sparks generated from magnet contact.

・Pileup of adhesive, paint or other flammable materials inside the machine

11/17 Heated chips generated during cutting the inner SUS plate ・Flammables piled at locations difficult to clean
/2013
13-02k-1 Flushing booth with electric saw dropped on the piled-up adhesive chips and ・Implementation of regular inspection and cleaning

generated smoke. ・Measures against static electricity in preventing dirt spattering and piling

up.

13-02k-2 11/23 Adhesive Plastic sheet used in the booth was charged and seemed to ・Accumulation of flammables and measures against static electricity
14-02k /2013 spraying booth generate electrostatic sparks, which ignited the sheet, generation
14-03k generating smoke.
09/16
/2014 Pressure Although the heater was turned on without opening the LLC ・Level sensor correctly works to detect anomaly.
vibration tester supply valve, it continued to work and generated smoke, for ・If not, repair the sensor.
08/18 the level sensor had been removed.
/2014
Dust tended to pile up on the electric breaker terminal due to ・Check for dust and loose screws of the Mitsubishi breakers whose type

- its structure, and grounding may have occurred via tightening codes end with KB.

screws.(Root cause was not identified) ・Applicable breaker is regularly replaced per schedule.

14-04k 10/20 Curing machine Heater wiring for temperature regulating unit deteriorated due ・Contamination/flaw of temperature regulating unit heater wiring
/2014 to oil contamination/dust accumulated on the coating flaw, ・Oil contamination or dirt, if any, is cleaned or serviced.
which generated tracking and smoking from the coating.

GSS-M

Machine Safety Design Manual part

Format 1 GSR-0Z-001
Page 1/3

Class Sumitomo Riko Safety Standard Classification GSM䠉00䠉002-
Name number
Machine Safety Design Standards
Established Date: 01/04/2015

Last Revised Date: 01/04/2015

1. (Objective)
The objective of this standard is to stipulate the basic matters for machine safety design in order to
introduce safe machines/equipment at Sumitomo Riko and its subsidiaries.

2㸬(Scope of Application)
This standard applies from planning to delivery to the user departments of the machines/equipment for
manufacturing, research, tests, inspections, safety, pollution prevention and environmental
conservation, power supply, and generating, receiving and transforming electricity. (Appendix 1)

3. (Definition) Definitions
Risk assessment (RA) implemented at the machine design phase set in GSM-00-003
Terms “Machine Design Risk Assessment Procedures
Design RA Methodology aimed to reduce risks by utilizing the Inherently Safe Design Measure, the
safeguarding and Complementary Protective Measures, and the information for use in this
3 Step Method order
Inherently Safe Design Measure to eliminate and restrict exposure of risk sources in the design phase in order
Measure to reduce risks
Safeguarding and Measures to protect associates from risk sources and risks that cannot be eliminated o
Complementary Protective
Measures r reduced with the Inherently Safe Design Measure by utilizing safeguarding structures

Information for Use such as guards and safety light curtains, and emergency stop systems

Specifications Required Information necessary to correctly and safely use machines/equipment including letters,

Purchase Specifications characters, signals, sounds, and others that are easy to understand for users.
In-line Machines/Equipment
Machine Safety Inspection Specs required to manufacture or modify the machines presented to the machine

engineering section from the machine planning section such as machine’s capacity,
dimensions, delivery date, and budget, etc.

Detailed specs required for the machine engineering section to have machine

makers design machines/equipment

A group of machines mechanically and electrically connected and lined up in sequence

Inspection to verify the safety of machines in accordance with GSM-00-004 “Machin

e Safety Inspection Standards” and judge whether or not machines can be used.

4. (Machine Design Principle)
(1) The machines/equipment introduced to Sumitomo Riko and its subsidiaries must be designed and

manufactured in accordance with the requirements set in the regulations of the countries or regions
of their locations and the Sumitomo Riko Safety Standards for Machinery.
(2) The machines/equipment introduced to Sumitomo Riko and its subsidiaries must go through a risk
assessment (hereafter called “Design RA) in their design and manufacturing phases in order to
consider strategies to reduce risks to an acceptable level based on the 3 step method.
(3) The Machine Engineering Section must confirm the safety of machines/equipment through machine
safety inspections before use.

5. (Procedure)
(1) The Machine Planning Section must submit required specifications to introduce safe machinery.
(2) The Machine Engineering Section must compile purchase specifications based on the required

specifications submitted by the machine planning section and present them to machine makers
except for commercially-available machines/equipment.

Drafted by Approved by Person Responsible

Chairperson of Machine Safety WG General Manager of Chair person of
Safety and Health Department CSR Safety and Health Committee

Takayuki Noguchi Hiroshi Noso Ken Kono Rikizo Tatsuta

Classification Number GSM䠉00䠉002 Format 1 GSR-0Z-001
Page 2/3


(3) The Machine Engineering Section must have machine makers conduct the Design Risk
Assessment in the machine design and manufacturing phases to reduce safety risks.

(4) The Machine Engineering Section must conduct the Design RA in the following cases to

reduce safety risks:
ձ When the Design RA cannot be held according to the circumstances of the
machine makers
ղ When the compliance with the machine safety standard is impossible due to
manufacturing methods, etc.
ճ When machines/equipment made by multiple makers are introduced as in-line
machines/equipment
մ Commercially-available machinery. In this case, the said section shall have its
machine makers submit information such as remaining safety risks and conduct the

Assessment based on this information.
(5) The Machine Engineering Section must make sure that the resulting information on safety

risks is clarified after the risks have been reduced through the Design RA.

(6) The Machine Engineering Section must have the safety of machines/equipment proven
through machine safety inspections.

6. (Approval)
The Machine Engineering Section must inform that it has confirmed the results of the Design
RA and acquire approval from the head of the machine engineering section or his/her
equivalent by the time the relevant machines/equipment are introduced.

7. (Documentation)
(1) The Machine Engineering Section must document the results of the Design RA before using
the relevant machines/equipment are introduced.
(2) The Machine Engineering Section must have machine makers submit the remaining safety
risk information (including instruction manuals) by the time the relevant machines/equipment
are used. Furthermore, information about the safe use of the machines/equipment must be
documented as part of the remaining safety risk information.
(3) The Machine Engineering Section must compile the documents for the safe use of the
relevant machines/equipment by the time of use if it cannot obtain the remaining safety risk
information from machine makers due to their circumstances.
(4) The Machine Engineering Section must save the original documents as long as its
department or base has the relevant machines/equipment.

8. (Communication)
The Machine Engineering Section must explain all necessary information on the safe use of
machines/equipment to the Machine Using Section by the time of use.

9. (Education/Training)
The Machine Engineering Section shall make efforts to educate/train its department or base
regarding relevant legislation, machine safety standard, and the Design RA in order to promote
introducing safe machines/equipment.

(Supplemental Provisions)
1.The responsible department for this standard shall be the Safety and Health Department of

Sumitomo Riko Company Limited (Global Safety Standards promotion Office).
2.This standard takes effect from April 1, 2015.
3.Specific management methods for the matters described in this standard shall be based upon the

classification number GSM-0G, GSS-M “Machine Safety Design Manual.”

Appendix 1 (Machines/equipment in the scope of application)
The following table shows machines/equipment for manufacturing, research, tests, inspections,
safety, pollution prevention and environmental conservation, power supply, and generating,
receiving and transforming electricity. For the matters indicated as “Consultation Needed” in the
Class section, consultation shall be made with the Safety and Health Section of the relevant
department or base in order to make a decision.

Type Structure / Use Example and Description Class
Land
Reinforced concrete, metal, Headquarters building, AV plants, company Out of
Building Scope
Out of
bricks, stones, blocks, wooden dormitories Scope

Classification Number GSM䠉00䠉002 Format 1 GSR-0Z-001
Page 3/3


Auxiliary and other simple structures Elevators Consultation
Equipment for (zinc-roofed and temporary, Needed
Buildings etc.) Used for extensive areas through ducts
Battery and power supply In Scope
Structure facilities Heavy oil tanks and carbon silos
Electric facilities Asphalt, concrete and blocks Out of
Machines/Devices Elevators Ground and tennis court Scope
Fire extinction, disaster alarm Planted grass, trees and lawns
Tools system Rubber products manufacturing facilities such In Scope
Fixtures Water supply, drainage, hygiene as AV rubber, hoses, and chemical products
and gas facilities Facilities used for new principles and new Out of
Motor Vehicles Air-conditioning, heating and product research Scope
and Transport ventilation facilities Forming machines, NC vulcanizing machines, Out of
Equipment Air curtains, automatic doors die cast machines, boring and milling Scope
Arcades and shading facilities machines, lathes, cranes, sedimentation and
Partitions flotation devices, oil water separating Consultation
Sewage treatment storage tank devices, and dust collectors, required
and metal structures
Sewage drains and tanks Jigs and tools In Scope
Incinerators, chimneys and Out of
wells Molds and rolls Scope
Steel water tanks and oil tanks Office desks, TVs, air conditioners, and curtains
Metal structures for advertising Telephones, PCs, and servers
Paved ground Electronic scales
Sports facilities Cameras and microscopes
Plant greening areas and
gardens Containers and drum cans
Rubber products manufacturing Vending machines and incinerators
facilities, plastic products Automatic guided vehicle (AGV), towing
manufacturing facilities, mold vehicles
manufacturing facilities, Fire engines, trucks and automobiles
research facilities (including
technological and development
facilities), metal parts
manufacturing facilities, repair
and tooling facilities, sewage
treatment facilities, and smoke
treatment facilities
Food service facilities

Measuring, inspection,
attachment, forming, stamping,
and cutting tools
Molds and rolls
Furniture, electric appliances
and gas equipment
Office devices and
communications devices
Clocks, testing devices and
measuring devices
Optical devices
Signboards and advertisement
equipment
Containers and safes
Medical devices
Other fixtures
Forklifts
Self-running motor vehicles

Passengers Cars
Metal carts

Sumitomo Riko Group

Machine Safety Design

Sumitomo Riko Company Limited
Global Safety Standard promotion Office

Sumitomo Riko Group

Purpose

Introducing safe machines is essential to create a safe and secure
workplace. In order to do that, safety must be ensured from the design
phase. This material gathers information necessary for associates
involved in machine introduction to understand.
This has been compiled based on the International Standards (ISO)
related to machine safety and Sumitomo Riko Global Safety Standards
for Machinery so that Sumitomo Riko and its domestic and overseas
Group Companies can utilize it globally.

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Table of Contents Sumitomo Riko Group

1. System of Introducing Safe Machines P5
P10
1-1. System of Introducing Safe Machines P19
1-2. Principles of Machine Design
1-3. GS Certification P21
P22
2. Risk Reduction Process
P23
2-1. Risk Reduction Process from a Standpoint of Designers P25
2-2. Risk Assessment and 3 Step Method
P29
3. Risk Assessment P33

3-1. What is Risk Assessment? P34
3-2. Relevant Terms P36
P38
4. 3 Step Method P43
P45
4-1. Outline of Risk Reduction Measures P47
4-2. Examples of Risk Reduction Measures P48

5. Inherently Safe Design Measures Ｐ2/Ｐ135

5-1. Outline of Inherently Safe Design Measures
5-2. Description of Inherently Safe Design Measures
5-2-1. Consideration of Geometrical Factors and Physical Aspects
5-2-2. Taking into Account General Technical Knowledge of Machine Design
5-2-3. Choice of Appropriate Technology
5-2-4. Applying Principle of Positive Mechanical Action
5-2-5. Provisions for Stability

Table of Contents Sumitomo Riko Group

5. Inherently Safe Design Measures P51
5-2-6. Provisions for Maintainability P52
5-2-7. Observing Ergonomic Principles P58
5-2-8. Electrical hazards P65
5-2-9. Pneumatic and Hydraulic Hazards P69
5-2-10. Applying Inherently Safe Design Measure to Control Systems P70
5-2-10-1. General P72
5-2-10-2. Starting of an Internal Power Source/Switching on an External Power Supply P72
5-2-10-3. Starting/Stopping of a Mechanism P73
5-2-10-4. Restart after Power Interruption P74
5-2-10-5. Interruption of Power Supply P75
5-2-10-6. Use of Automatic Monitoring P76
5-2-10-7. Safety Functions Implemented by Programmable Electronic Control Systems P80
5-2-10-8. Principles Relating to Manual Control P82
5-2-10-9. Control Mode for Setting, Teaching, Process Changeover, Fault-Finding, Cleaning or Maintenance P84
5-2-10-10. Selection of Control and Operating Mode P85
5-2-10-11. Applying measure to achieve electromagnetic compatibility (EMC) P87
5-2-10-12. Provision of Diagnostic Systems to Aid Fault-finding P88
5-2-11. Minimizing Probability of Failure of Safety Functions P93
5-2-12. Limiting Exposure to Hazards through Reliability of Equipment P94
5-2-13. Limiting exposure to hazards through mechanization or automation of loading (feeding) P95
5-2-14. Limiting exposure to hazards through location setting and maintenance points outside danger zones

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Table of Contents Sumitomo Riko Group

6. Safeguarding P96
P108
6-1. Guideline for Selecting Safeguards (Guards and Protective Devices) P112
6-2. Requirements for Design of Guards and Protective Devices
6-3. Safeguarding to Reduce Emission P114
P118
7. Complementary Protective Measures P119
P120
7-1. Requirements for Emergency Stop Function P121
7-2. Measures for the Escape and Rescue of Trapped Persons
7-3. Measures for Isolation and Energy Dissipation P123
7-4. Provisions for Easy and Safe Handling of Machines and Heavy Component Parts P125
7-5. Measures for Safe Access to Machinery P125
P128
8. Information for Use P131

8-1. General Requirements P135
8-2. Location and Nature of Information for Use
8-3. Signals and Warning Devices
8-4. Markings, Signs (Pictograms) and Written Warnings
8-5. Accompanying Documents (in Particular – Instruction Handbook)

9. Documentation of Risk Assessment and Risk Reduction

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1. Introduction System of Safe Machines Sumitomo Riko Group

1-1. Introduction System of Safe Machines (Planning ― Design)

Ordering Machine Maker Machine Engineering Dept. Machine Planning Safety and Health Dept. Machine Using
Dept. Dept. Consultation Dept.
Estimate Concept Design Required Consultation
Issuance of Estimate Request Specs Machine Discussion on
Order Investment Plan Specs
Sheet Process Design
Order
Sheet Estimate Budget Calculation Budget Draft Check for Report
Make Purchasing Calculation to Public Office

Purchase Request Specs Drafter
Slip
Approval

Purchase Purchase Request
Specs
Order Reception,
Detailed Design

Design RA

・Identify risks.
・Estimate and assess risks.
・Consider risk reduction measures.

Machine engineering Dept. conducts design RA when･･･※１

・The machine maker cannot implement design RA. Request for Design
・Compliance with the machine safety standards is found difficult Confirmation Confirmation
such as manufacturing problems.
・Machines integrated into a line ・Marketed products Design Confirmation

Design Confirmation Change
Request
Delivery Confirmation

Confirmation

drawing NG Approval

from Dept.

Manager
※2 OK

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1. Introduction System of Safe Machines Sumitomo Riko Group

1-1. Introduction System of Safe Machines (Manufacturing ― Introduction)

Machine Maker Machine Engineering Dept. Machine Planning Safety and Machine Using Machine
Dept. Health Dept. Dept. Maintenance

※2 Safety
Confirmation
Machine Making

Design RA ※1 Safety Safety
Confirmation Confirmation
・Identify risks.
・Estimate and assess risks.
・Consider risk reduction measures.

Correction Safety Decision
Design RA Sheet
NG Confirmation
OK

Machine
Introduction

Design RA
・Documentation (design RA result, info about remaining risks) ※1

Documentation
Check

Approval from
Dept. Manager

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1. Introduction System of Safe Machines Sumitomo Riko Group

1-1. Introduction System of Safe Machines (Introduction ― Machine Safety Inspection)

Machine Maker Machine Engineering Dept. Machine Safety and Machine Using Machine
Planning Dept. Health Dept. Dept. Maintenance

Explanation of Request for Selecting Selection of Selection of
Operation Special Operator Special Operator Special Operator

Installation Operation Approval from Approval from
Test Drive Check Dept. Manager Dept. Manager

Check Explanation

※5 Application for Machine Operation Check Operation Check
Safety Inspection

Application for Inspection Inspection Inspection Inspection
Safety Inspection Accepted Accepted Accepted Accepted

Design RA Sheet

※3 Machine Safety Inspection
GS Compliance Label Operated by Special Operator
Label Attached
Decision
NG

Ok or NG

OK
Limited Approval for

Operation
Issuance of GS
Compliance Label

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1. Introduction System of Safe Machines Sumitomo Riko Group

1-1. Introduction System of Safe Machines (Machine safety inspection Passed ― Operation)

M設a備chiメneーMカakーer Mach設ine備En技gin術ee部rin署g Dept. Machine Planning Safety and Health Machine Using Machine
Dept. Maintenance
Dept. Dept.

Completed Completed Takeover
Book Book
・Instruction Manual
Completed Book ・Operation Instructions
Submitted ・Providing info on the remaining risks.

Received Drafting and rolling ※4 Drafting and rolling
out implementation out implementation
rules (education and Safety Inspection rules (education and
Application Form
display, etc.) display, etc.)

Application for Application for
Work Safety Work Safety
Inspection Inspection

NG Inspection
※4 Accepted

OK or NG

OK
Ａｐｐｒｏｖａｌ for

Operation

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1. Introduction System of Safe Machines Sumitomo Riko Group

1-1. Introduction System of Safe Machines (Machine Safety Inspection Failed ― Operation)

Machine Maker Machine Engineering Dept. Machine Planning Safety and Machine Using Machine
Dept. Health Dept. Dept. Maintenance

※3 Application Form ※3
for Special Use
Instructions for
Defect Correction Application for
Special Use

Defect Correction

Approval Dismissed
Judgment ※3

Check Approval
※5
Special Use
※3

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

Rules to be followed to prevent accidents/injuries caused by machines

(1) Compliance with laws and regulations

(2) Compliance with machine safety standards

(3) Implementation of design risk assessment

(4) Risk reduction measures by 3 step method

(5) Implementation of machine safety inspection

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(1) Compliance with laws and regulations

Japan → Industrial Safety and Health Act, enforcement orders, rules, standards, and guidelines

Ordinance on Safety of Boilers and Pressure Vessels (boiler rules)
Ordinance on the Prevention of Organic Solvent Poisoning (organic rules)
Fire Service Act, Air Pollution Control Act, and Water Quality Pollution Control Act

Overseas → U.S. ＯＳＨＡ（Occupational Safety and Health Act

China Chinese Safety Production Act
Europe EU Machinery Directive

Diverse rules and regulations (hard to understand)

Report, Structure Standards, Laws and regulations must be abided by.
Certification Acquisition →Penalty, Litigation

Don’t know Investigate (correct info), Teach (education in departments)
Listen (Japan: Safety and Health Dept., Overseas: Safety Dept. at each base)

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(2) Compliance with machine safety standards

Machine Safety Standards ･･･ Rules to ensure safety of machines

introduced to Sumitomo Riko

International Standards (ISO) Established, revised by Approved by
Machine Engineering Dept. Machine Safety WG
Domestic Regulations Safety and Health Dept.

Information sharing about past
accidents/injuries

Overseas Meet both requirements.

When the machine safety standards differ from the (comply with the stricter one)
regional rules and regulations,

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(2) Compliance with machine safety standards

International Standards (ISO) System ・Concept of Safety and Risks
・Requirements for Risk Assessment
ISO / IEC Guide 51 ・Risk Reduction Methods
・Hierarchical Structure of Standards

ISO: Mechanical Ａ IEC: Electric

Safety of Machinery（ISO12100/JISB9700） Basic Safety
Standard
Electric Machines Safety Standard
Interlocking standard（ISO14119/JISB9710） Ｂ （IEC60204-1/JISB9960-1）
Guard System Standard（ISO14120/JISB9716） Sensor General Safety Standard
（IEC61496-1,2,3/JISB9704-1,2,3）
System Safety Standard（ISO13849-1/JISB9705-1）
Display, Marking（IEC61310/JISB9706）
Safety-Related Parts Standard（ISO13849-2） Group Safety Standard
Emergency Stop, Both Hand Operation, Safety Functional Safety Standard (IEC61508/JISC0508）

Distance･･･ Ｃ Switch, EMC, Explosion-Proof･･･

Machine Tool, Industrial Robots, Elevator･･･

Safety Standards for Individual Machine

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(2) Compliance with machine safety standards

Comparison between ISO and Sumitomo Riko Standards

①Basic Safety Standard (A Standard) Guide 51

Stipulates the principles, terms, and basic requirements for design. A
B
Procedures of risk assessment (RA) and safety design, etc. C
→ GSM-00-003 “Machine Design Risk Assessment Procedures (A Standard)

②Group Safety Standard (B Standard)

Stipulates safety-related affairs or safety distance applied to a wide range of machinery.
Guard, emergency stop, safety light curtain, and explosion-proof, etc.

→ Global Safety Standards for Machinery (B Standard)

③Individual Machine Safety Standard (C Standard)

Stipulates detailed safety requirements for individual machines or a group of machinery.
Robots, vulcanizing machines and adhesive treatment machine, etc.
→ Safety Standards for Machinery, Common Machine Specifications for Each Dept. (C Standard)

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(2) Compliance with machine safety standards

Comply with standards for individual Ｃ Standard Ｃ標Ｃ準 Standard Ｃ標Ｃ準Standard
machinery Ｃ標Ｃ準 Standard Ｃ Standard Ｃ Standard

(Safety Standards for Machinery / C standard)

N/A

Comply with standards applied to a wide
range of machinery

(Safety Standards for Machinery / B standard)

N/A

Comply with RA (A Standard)

Guide 51 Major Premise Image of Standard Structure BＢSt標an準dard ＊Example of Applying
(RA) A/B/C Standards to
A Machinery
B Compliance
C Order AＡSt標and準ard

図 規格イメージ（株式会社キーエンスHP リスクアセスメントとは http://www.keyence.co.jp/switch/special/safety/about/machine/）

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(3) Implementation of design risk assessment

Risk assessment implemented at the machine design phase

Design Risk Assessment (Design RA)

Purpose
For introducing safe machines,
reduce risks to the allowable levels at the design phase

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(4) Risk reduction measures by 3 step method

3 Step Method
Considering risk reduction measures by prioritizing them.

Step 1 Inherently Safe Design Measures Consider in this order.
(detail explained later)
Eliminate or reduce risks.

Step 2(-1) Safeguarding and
Step 2(-2) Complementary Protective Measures

Enclose or stop risks.

Step 3 Providing Information for Use
Be careful.

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-2. Principles of Machine Design

(5) Implementation of machine safety inspection
Are risks reduced? (allowable risks)
Inspections necessary before operation in
order to prevent accidents/injuries

Conduct machine safety Safety Inspection Passed Label
inspections.
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Conduct inspections by personnel who has
knowledge about machine safety.

→GS Certifiers

1. System of Introducing Safe Machines Sumitomo Riko Group

1-3. GS Certification

GS Certification system regarding machine safety in Sumitomo Riko Group.
The following are the necessary knowledge and responsibilities for each
Certification duty.

GSM Safety manager who gives approvals and takes final responsibilities
GSE for ensuring machine safety.
GSI
Safety engineer who monitors and instructs the operational statuses
for machine safety through machine safety inspections

Safety inspector who owns the basic knowledge about machine safety and
checks residual risks through machine safety inspections.

GSD Safety designer who has expertise of machine safety, and plan, design
and introduce safe machinery.

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1. System of Introducing Safe Machines Sumitomo Riko Group

1-3. GS Certification

De pt. Responsibility GS Cert ified Associat es Personnel Involved Appointed by Approved by Roles

Safety and Health Department Safety Manager Plant Managers and Manager of the Safety and Health Department ・Final responsibility for safe machine
Safety Management
GSM Presidents of Subsidiaries at the Head Office operations at each base

Safety Engineer Staff of the Safety and ・Education/training for machine
GSE Health Department of the safety
Head Office ・Monitoring and instructions about
Safety Design safe machine operations in machine
Manager St aff of t he Safet y GSM safety inspections
GSM-D Environment Sect ion, t he ・Safety inspection members

Safety Designer General Affairs Sect ion and the ・Responsible for machine safety in
ＧＳＤ each business
Safet y and Healt h Sect ions at
・Responsible for machine safety at
bases each base

Head of the Machine General Managersand Safety and Health ・Special ability for machine safety
・Plan, design and introduction of safe
Engineering Department of Department Managers Dept. Manager at the machines
the head office ・Safety inspection members
at the Head Office Head Office
Product ion Engineering ・Responsible for safe machine
Business Units / R&D / Manufacturing Support Machine Design operations at each department
Managers at bases

(Machine Engineering Dept.

Managers at bases)

St aff of t he Plant Engineering GSM-D
Dept . and the Machine
Engineering Dept .

St aff of t he Product ion
Engineering Dept . at bases
(Staff of the Machine
Engineering Dept . at bases)

Safety Use Manager Manufacturing Dept. General Managers and Safety and Health
Department Managers Dept. Manager at the
GSM－I Managers, etc. at the Head Office Head Office

Machine Usage Safety Inspector Manufacturing Section Manager GSM－I ・Basic knowledge about machine
GSI Maintenance Engineering Section safety
Man ag er ・Safety inspection members
P lant Engineering Section Manager

Manufacturing Section Manager
P lant Engineering Section Manager
Machine Section Manager

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2. Risk Reduction Process Sumitomo Riko Group

2-1. Risk Reduction Process from a Standpoint of Designers Scope of Explanation

Risk Reduction Methodology in Risk Assessment
ISO 12100 3 Step Method

●Exchange risk reduction “information” to further reduce risks. (PDCA)

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2. Risk Reduction Process Sumitomo Riko Group

2-2. Risk Assessment and 3 Step Method

START Preparation for Designers are required to have a methodology to
Risk assessment
(5-3)

Detemination of thelimits of ensure machine safety. ISO
the machinery

Hazard identification Risk analysis 12100 / JIS B9700
(5-2 Section)

Risk estimation ① Conduct risk assessment
Calculate risks of machines to judge the
Risk evaluation Risk evaluation YES necessity of risk reduction.
(5-3 Section) Are other hazards

Has therisk been YES Docmentation generated?
adequately (7 Section)
reduced? END YES ② Risk reduction with 3 step method

NO YES Risk reduction Risk re-evaluation YES
(5-4S ecti on) →Confirmation of the adequacy,
Can the hazard be
remove? and Approval. (5-5.6 Section) Step 1 Inherently Safe Design Measures

NO Risk reduction by Is the intended risk
Inherently safe design reduction achieved?

mesures NO Step 2 Safeguarding and Complementary

Can the risk be reduced YES Is theintended risk
reduction achieved?
by inherently safe design
NO
measures?

NO Protective Measures

Can the risk be reduced by YES isk reduction by
guards, protective devices? safeguarding

NO implementation of

complementary Step 3 Providing information for Use
protective mesurements

YES Can the limits be specified NO Risk reduction by Is the intended risk YES
again? information for use reduction achieved?
Conduct risk reduction in an
NO

Guidelines for comprehensive safety standards for order of Step 1→2→3
machinery referring to separate diagram

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3. Risk Assessment Sumitomo Riko Group

3-1. What is Risk Assessment?

Risk assessment (RA) refers to a series of procedures ranging from revealing all

potential risks and hazardous property, estimating potential risks, prioritizing

countermeasures, and conduct risk reduction activities.

START Preparation for
Risk assessment
(5-3) RA should be conducted at the machine’s design

Deteminationof thelimits of
the machinery

Hazard identification Risk analysis phase!
(5-2 S ection)

Risk estimation Benefits of conducting RA at the design stage.

Risk evaluation Risk evaluation YES Inherent safety can be ensured
(5-3 S ection) Are other hazards → Most effective safety measure

Has therisk been YES Docmentation generated? Additional safety measures can be avoided.
adequately (7 Section) → Costs can be eventually slashed.
reduced? END YES
Consider safety at the design phase together with
NO YES Risk reduction Risk re-evaluation YES quality, cost, and delivery.
(5-4S e cti on) →Confirmation of the adequacy,
Can the hazard be
remove? and Approval. (5-5.6 Section)

NO Risk reduction by Is theintended risk
Inherently safe design reduction achieved?

mesures NO

Can the risk be reduced YES Is the intended risk
reduction achieved?
by inherently safe design
NO
measures?

NO

Can the risk be reduced by YES isk reduction by
guards, protective devices? safeguarding
implementation of
complementary
protective mesurements

NO

YES Can the limits be specified NO Risk reduction by Is theintended risk YES
again? information for use reduction achieved?

NO

Guidelines for comprehensive safety standards for
machinery referring to a separate diagram

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3. Risk Assessment Sumitomo Riko Group

3-1. What is Risk Assessment?

Risk assessment is the most basic task to secure safety.
Repeat the same process until risks are reduced to the allowable levels.

Risk Analysis Start Put together machine specs and
how to use
Decide on restrictions of
machinery Discover hazard sources
Quantify risks with decision table
Identify hazard sources

Estimate risks Prioritize risks according to
severity

Risk Assessment Evaluate risks Consider/implement safety
measures

Risks properly reduced? No Risk reduction
Yes 3 step method

Documentation For details of relevant terms and how to proceed with risk
assessment, refer to the following sources.
Complete ・ISO 12100 / JIS B9700
・Machine Design Risk Assessment Procedures

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3. Risk Assessment Sumitomo Riko Group

3-2. Relevant Terms

① Definition of risks･･･Combination of hazard probability and severity

Hazards Risks

Hazard Source

No injury occurring when no one is around Possibility of an injury occurring when a person is around the hazard.
the hazard.

Illustration: Description of Risks図(Wリebスsクiteのo説f明M（in厚is生tr労y働o省f HHPeal職th場aのnd安W全サelイfaトreh:ttWp://oanrzkepnilnafco.emhslawf.egtoy.jps/riitsek/shytotkpu:h//ina0n7z.hetmnil）nfo.mhlw.go.jp/risk/syokuhin07.html)

Definition of safety ･･･ No unacceptable risks

Without the lion (hazard source) → Safe (No unacceptable risks)

(Zoo) Without and lion → Customers would not come.

Lion in a cage → Risks reduced to an allowable level

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3. Risk Assessment Sumitomo Riko Group

3-2. Relevant Terms Unacceptable Risks

② Safety･･･Freedom from unacceptable risks.

ALARP Area

Widely Acceptable Risks Acceptable Tolerable Risks
Risks

Residual Risks Cost Effectiveness

Safety Risk
Reduction

Risk Low High

ALARP（As Low As Reasonably Practical） Example: Automobiles
Engaged in risk reduction as long as it is reasonably feasible. Developing cars anybody can drive. Cost ↑
→Driver’s license for 18 years or older,
lectures for elderly drivers

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3. Risk Assessment Sumitomo Riko Group

3-2. Relevant Terms Table: Difference in the concept of safety between Japan and the West

② Definition of Safety

Japan West (Global)
Accidents/injuries will happen according to technoligical levels
Accidenta/injuries could be permanently prevented with efforts. regardless of efforts.

Humans are the main cause of accidents/injuries. Human Accident/injury prevention is a technical matter. Technical
countermeasures are prioritized over technical/technological countermeasures are prioritized over human countermeasures.
countermeasures
Safety can be secured by establishing a control structure, Safety cannot be secured without technical enhancement as humans
educating/training personnel, and strengthen regulations. do make mistakes.

Aim to ensure safety for humans and facilities with the Industrial Take technical countermeasures to prevent serious accidents/injuries
Safety and Health Act and regulatins are strengthened every time as well as ensure machine safety. Make efforts to establish
an accident/injury occurrs. tchniques/technology to reduce their severity.

Safety is basically free. Safety basically needs costs. Risk Assessment

Reluctant to recognize the necessity of costs for safety. Willing to pay the costs for safety.
Deal with visible "specific hazards" with the minimum cost and Reveal hazard sources, assess their risks, and pay the costs based
reluctant to pursue technical countermeasures for accidents/injuries on the assessment results. Make efforts to reduce possible
that haven't happened. accidents/injuries. Various techniques and tools invented for risk
reduction.

Techniques to eliminate risks detected. (Hazard detection Techniques to logically verify safety (hazard checking techniques)
techniques)

Stress frequency rate (number of accidents/injuries) Stress severity rate (serious accidents/injuries)

Masao Mukaidono: Basic concepts about safety and risks in Japan and the West

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3. Risk Assessment Sumitomo Riko Group

3-2. Relevant Terms

② Hazard Source･･･Potential sources that could cause harm
ISO 12100 classifies such sources into 10 items.

No. Hazard Source Examples of Hazard Sources
1 Mechanical
Cause Result

Angular areas Cuts

Moving element Being caught

Rotating element, etc. Being trapped, etc.

Arc Burns

2 Electric Charging area Electric shock

Overload, etc. Fire, etc.

3 Thermal Radiation from heat source Burns
Explosion Dehydration, etc.

4 Noise Sound-emitting pneumatic device Ear ringing
5 Vibration
6 Radiation Friction, etc. Fatigue, etc.
7 Materials and Substances
Vibration device Discomfort
8 Neglecting Ergonomics Unbalance, etc. Lower back disorder, etc.

9 Machine Using Environment Electromagnetic wave Burns
10 Combinations of Hazard Sources Laser, etc. Genetic mutation, etc.
Flammables Fire
Dust Explosion
Gas, etc. Poisoning, etc.

Location of indicators Discomfort
Glare Fatigue
Posture, etc. Stress, etc.
Water Slippage
Humidity Burns
Snow, etc. Suffocation, etc.

Repeating motion and Dehydration
High temperature, etc. Fatigue, etc.

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4. 3 Step Method Sumitomo Riko Group

4-1. Outline of Risk Reduction Measures

The following is the detail of safety measures based on the 3 step method. (details
described later)

Priority: Step1→2→3

Step 1: Inherently Safe Design Measures Diagram: Guidelines on the Comprehensive Safety Standards

・Eliminate hazard sources or reduce risks. for Machinery This Part
e.g. Eliminate protruded sections exposed
to human contact. Use materials with lower toxicity.

・Eliminate or reduce the necessity of humans
entering hazardous areas.
e.g. Structure allowing them to work from outside

hazardous areas

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4. 3 Step Method Sumitomo Riko Group

4-1. Outline of Risk Reduction Measures

Step 2 Safeguarding and Complementary Protective Measures

Safeguarding

When hazard sources cannot be removed or risks cannot be reduced by the Inherently

Safe Design Measure,

→Protective measures with the use of safeguarding Mechanical and

Isolation from hazard sources → Guards electric protection

Eliminate hazard sources → Protective system

e.g. safety light curtain, mat switch, enabling device, etc.

Risk Source (robot in this case) Safety Light Curtain

Robot stops when the
light curtain is blocked.

Fixed Guard (OMRON Website: Risk Reduction Measures) Protective Device (OMRON Website: Risk Reduction Measures)
http://www.fa.omron.co.jp/solution/sysmac/safetynavigator/safety_expert/iso12100_02.html） http://www.fa.omron.co.jp/solution/sysmac/safetynavigator/safety_expert/iso12100_02.html）

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4. 3 Step Method Sumitomo Riko Group

4-1. Outline of Risk Reduction Measures

Step 2 Safeguarding and Complementary Protective Measures

Complementary Protective Measures
Measures to supplement safety functions
Technical and engineering measures that are neither “inherently safe design” nor
“safeguarding.”

・Emergency stop Human-dependent
・Escape or rescue methods for the trapped protection
・Energy cutoff and dispersal procedure
・Safe machine handling methods in transportation
・Safe access method to machinery

Emergency Stop Switch（IDEC Website: Emergency Stop Switch) Breaker Handle (Midori Anzen Co., Ltd. Website: Lockout System) http://lo.midori- Lockout Handle (Midori Anzen Co., Ltd. Website: Lockout System)
http://jp.idec.com/ja/technology/safety/guide/safety02.html）
sh.jp/?page_id=30） http://lo.midori-sh.jp/?page_id=30）

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4. 3 Step Method Sumitomo Riko Group

4-1. Outline of Risk Reduction Measures

Step 3 Providing Information for Use
The following two measures are provided to the users.
・Information on the correct (intended) ways of using machines
・Information on residual risks (risks that could not be reduced technically)

Specific methods
Instruction manuals, signs, warning labels, signals and alarms, etc.

However, these are completely dependent on human behaviors and would not function
effectively without compliance.

Warning Label (Midori Anzen Co., Ltd. Website: PL Warning Label)
http://ec.midori-anzen.com/shop/g/g4066203110/）

Priority
①Inherently Safe Design (fundamental) ＞ ②Safeguarding (mechanical and electric)

＞ ③Complementary Protective Measures (human) ＞ ④Information for Use (human)
Consider measures independent of human behaviors as much as possible!

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4. 3 Step Method Sumitomo Riko Group

4-2. Examples of Risk Reduction Measures

Electric Hazard Source ･･･ Blade
Fan Hazardous Event ･･･
Risk Reduction Measures Sticking fingers in between the cover and
cutting them on the blade.
･･･ Narrowing the gap on the cover.

Putting a net over the cover.

After Removing the Cover ･･･ Warning to prevent the use

Safeguarding Information for Use

Electric Fan (Yamazen Fan Cover (Yamazen website: Electric Fan) Fan Cover Instruction Manual (Yamazen Website:
http://www.yamazen.co.jp/common/files/2014_fan_ca (Tokyo Life Web: Injury prevention by the fan cover) Electric Fan)
Website: Electric Fan) https://www.shouhiseikatu.metro.tokyo.jp/anzen/test/documents/ http://www.yamazen.co.jp/common/files/yama
talog/#8） zenbook/YLM-G303）
http://www.yamazen.co.jp/yamazenbo 60l7r500.pdf）

ok/product/product01/YLM-G303）

Inherently Safe Design Measures? Please fully observe safety precautions to prevent accidents/injuries.
●Do not use the electric fan without the guard. It is very dangerous.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-1. Outline of Inherently Safe Design Measures

3 step method to reduce risks

Safeguarding Sometimes doesn’t function or become disabled.

Information for Use non-compliance could occur.

Inherently Safe Effectiveness could be maintained easily.
Design

Therefore, Most Important！

First Step for Risk Reduction Ｐ34/Ｐ135

5. Inherently Safe Design Measures Sumitomo Riko Group

5-1. Outline of Inherently Safe Design Measures

Inherently Safe Design 2 Main Concepts:

Eliminate hazard sources. Reduce the impact of hazard sources.

e.g. Remove the lion. Change the lion to the cat.
→Change hydraulic to pneumatic and manual

Eliminate chances of humans contacting hazard sources.
e.g. Automatic feeding to the lion.
→ Auto loader

Can this apply to machine design? (quality, coast)
→Important to think at first

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2. Description of Inherently Safe Design Measures

Inherently Safe Design Measures

Measures by non-controlling methods Measures by controlling system

ISO12100 ISO12100　Chapter 6 ISO12100　6.2.11 and 6.2.12
/JIS　B9700 ・Considering geometric and physical aspects ・Application of Inherently Safe Design Measures to
・Principle of positive mechanical action between the controlling system
ISO13849-1 components ・Minimizing chances of safety function failure
/JIS　B9705-1 ・Safety and maintenance
・Observing ergonomic principles All Items
・Eliminating electric hazard sources, etc.

－

Fig. Classification of Inherently Safe Design ｛Reference: Masao Mukoudono International Standards of Safety Vol. 2 (2007) p.36｝

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-1. Outline of Inherently Safe Design Measures

ISO 12100/JIS B 9700 classifies the following regulations into 13 items.

1. Considering geometrical and physical aspects (ISO12100 6.2.2)
2. Considering general technical knowledge about machine design (6.2.3)
3. Selecting appropriate techniques (6.2.4)
4. Applying the principles of positive mechanical actions (6.2.5)
5. Provision about safety (6.2.6)
6. Provision about maintenance (6.2.7)
7. Observing ergonomic principles (6.2.8)
8. Electric/electronic hazard sources (6.2.9)
9. Preventing hazard sources of pneumatic and fluid pressure devices (6.2.10)
10. Applying inherently safe design to the controlling system (6.2.11)
11. Minimizing the probability of safety function failure (6.2.12)
12. Limiting exposure to hazard sources by the machine reliability (6.2.13)
13. Limiting exposure to hazard sources by mechanizing and automating feeding (supply) and
discharging (taking out) work (6.2.14)

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-1. Consideration of Geometrical Factors and Physical Aspects
(Reference: ISO12100/JISB9700 6.2.2)

①Measures from Geometrical factors

a) Design machines in ways that direct visibility is maximized to the work areas and hazardous areas

Establish methods to indirectly have visual contact in consideration of human visual features. e.g. reduce
dead angles, install mirrors/monitors, etc.

b) Consider the geometries of machine parts and their relative positions

●Expand the minimum gap between moving areas in order for the body to enter it safely.

e.g. Body: 500mm, Head: 300mm Refer to ISO13854/JIS B9711.

● Narrow the gap to prevent the body from entering it. Refer to ISO13857/JIS B9718.

e.g. Decide the dimension based on the guard height, limits and the opening size.

c) Eliminate sharp edges, angular and protruded part

sharp edges, rough surface, prongs, and openings that can trap the body or cloths
e.g. Chamfering, burring, covers to edges, etc.

d) Secure appropriate work positions and accessibility to the actuator.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-1. Consideration of Geometrical Factors and Physical Aspects
(Reference: ISO12100/JISB9700 6.2.2)

e.g. Indirect Visibility

Camera Monitor

Hazard Source

Check the inside of the machine with the monitor. →
No need to approach the hazard source.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-1. Consideration of Geometrical Factors and Physical Aspects
(Reference: ISO12100/JISB9700 6.2.2)

Example of Gap (Refer to ISO13854/JIS B9711 and ISO13857/JIS B9718 for detail.)

Table: minimum gap to avoid crush Table: Distance through openings (14 year olds or older)
(Excerpt from Table 1 in JIS B9711：2002) (Excerpt from Table 4 in JIS B9718 ：2013)

Minimum Gap Body Part Opening Safety Distance Sr
a (mm) Finger tip
Body Part 500 e≦4 Rectangular Square Round
300 Finger 4＜ e≦ 6
Body 180 Hand 6＜ e≦ 8 ≧2 ≧2 ≧2
Head 120 Arm 8＜ e≦ 10
Leg 50 10＜ e≦ 12 ≧10 ≧5 ≧5
Foot 120 12＜ e≦ 20
Toe 20＜ e≦ 30 ≧ 20 ≧ 15 ≧5
Arm 100 30＜ e≦ 40
Hand, Wrist and 40＜ e≦ 120 ≧ 80 ≧ 25 ≧ 20
fist 25
Finger ≧ 100 ≧ 80 ≧ 80

≧ 120 ≧ 120 ≧ 120

≧ 850 ≧ 120 ≧ 120

≧ 850 ≧ 200 ≧ 120

≧ 850 ≧ 850 ≧ 850

Red line indicates a scope of body parts restricted entry due to
the dimension of the op ening

Body Finger Foot Finger tip Finger Hand Arm
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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-1. Consideration of Geometrical Factors and Physical Aspects
(Reference: ISO12100/JISB9700 6.2.2)

e.g. Edge

No Instructions C Chamfering R Chamfering

Lower Risks

Burr on the Edge
(Reference: National Maritime Research Institute Website)
https://www.nmri.go.jp/eng/khirata/metalwork/basic/bari/index_j.html

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-1. Consideration of Geometrical Factors and Physical Aspects
(Reference: ISO12100/JISB9700 6.2.2)

② Measures from physical aspects

a) Limit the actuating force to a sufficiently small level not to cause moving areas becoming

mechanical hazard sources.
e.g. Hydraulic → Pneumatic → Manual

b) Limit kinetic energy, that is, the mass/velocity of movable elements.
e.g. Industrial robots teaching mode (speed limit: MAX250mm/s)

c) Restrict emission by focusing on the properties of the emission (radiation, discharge) sources.

1) Measures to reduce noise at its source

2) Add or reallocate mass, and change process parameters (vibration frequency and amplitude).
e.g. Rectifying unbalance, and sympathetic vibration prevention by changing inherent vibration frequency

3) Measures to reduce emissions of hazardous substances (hazard and particulates, etc.).
e.g. Switching from powder to granule, and changing grinding machines to milling machines

4) Measures to reduce radiation
e.g. Reducing radiation output to the minimally functionable level, and securing distance between the
radiation source and the operator.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-2. Taking into Account General Technical Knowledge of Machine Design
(Reference: ISO12100/JISB9700 6.2.3)

a) Mechanical Stress device, etc.)

e.g. Stress restriction by correct calculation, structure, and tightening methods)
Overload Prevention (Rupture disk, destroyed area for protection, and torque limit
Avoid fatigue in the elements under stress fluctuation
Static and dynamic balance of rotating elements

b) Materials and their properties

e.g. Resistance against corrosion, aging, and abrasion
(Hardness, tractility, brittleness, homogeneity (blow hole, etc.)
Toxicity, and inflammability

c）Emission（Radiation/discharge value)
e.g. Noise, vibration, hazardous materials, and radiation.

Should utilize technical specifications for design (standards, design
standards, and calculation methods, etc.)

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-2. Taking into Account General Technical Knowledge of Machine Design
(Reference: ISO12100/JISB9700 6.2.3)

Example of Overload Prevention Preventing accidents caused by
abnormal pressure

Around Boiler Steam

Safety Valve

Blower Steam
Boiler

Oil Supply

Safety Valve (Venn Co., Ltd. Website)
http://www.venn.co.jp/text/0006b/spdfdata/0006b_23s.pdf
http://www.venn.co.jp/catalog/products/sl-23h.pdf

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-3. Choice of Appropriate Technology (Reference: ISO12100/JISB9700)

Choosing a technique/technology used for a specific purpose can remove one or

more than one hazard source(s), or reduce risks.

For example,

a) for machines intended to use in an explosive atmosphere,

use of an appropriately selected pneumatic or hydraulic control system and the actuator
use of an electric device based on the inherently safe explosion proof（IEC60079/JIS C60079）

b）for specific production (e.g. using hazardous materials and solvents)

use of a device that can surely maintain temperature that is lower enough than an ignition temperature

c）use of an alternative device to avoid a high noise level

e.g. Pneumatic device → electric device (compressor + air cylinder → electric actuator)
Mechanical cutting → water cutting device (water jet) in a certain condition

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-3. Choice of Appropriate Technology (Reference: ISO12100/JISB9700)

Example of an Explosive Atmosphere

Electric spark energy is held below ignition energy. → Inherently Safe Explosion Resistance

Hazard Area Safe Area

Sparks Switch

Energy Power
Suppressing
Us危ing険haz物ardをou使s m用aterials Barrier relay
（トル(エtoluンene、, MMEKE,Ketなc.) ど） Element (IDEC Corporation Website)
http://jp.idec.com/ja/s/c806C/）
(barrier)

Barrier Relay (Nakamura Electric MFG. Co., Ltd. Website) http://www.ex-nakamura.co.jp/boubaku.html）

Safety Standards for Machinery
“Standards for Explosion-Proof Measures for Domestic Electric Machines”

Subject Machines
● When storing or handling hazardous materials that have the ignition point at 40℃ or below
● When storing or handling hazardous materials that have the ignition point above 40℃ in an environment

with temperature higher than the ignition point.
● When installing a machine in a place where flammable/explosive gas, steam and dust can stay within

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-4. Applying Principle of Positive Mechanical Action (Reference: ISO12100/JISB9700 6.2.5)

Positive Mechanical Action

One movable mechanical component operates inevitably depending on the motions
of another mechanical component through direct contact or via a rigid element.

Note: When allowing free moves by gravity or spring, etc., such condition would not be regarded as
a positive mechanical action.

NC Contact with Positive Actuation Structure Normal NC Contact and NO Contact

Contact detached by direct Contact doesn’t open due to
force transmission torque insufficient direct power transmission

Contact 固F定ixed接C点ontact
Welding
Contact Devices with Positive Actuation Structure
Welding Spring (IDEC Corporation Website) http://jp.idec.com/ja/s/c14MA/
Breakage
http://jp.idec.com/ja/technology/safety/guide/index.htm
Spring Defect
Symbol for Positive
Spring Defect Actuation Structure

Contact opens in spite of contact welding / Contact Movable Ｐ47/Ｐ135
spring breakage / spring defect Welding
可C動on接ta点ct

Contact Welding Force＞Spring Elastic Force Spring Defect/Breakage

Positive Actuation Structure (OMRON Website)
www.fa.omron.co.jp/product/sf_back/sf_back_pdf/safety-digest.pdf

5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-5. Provisions for Stability (Reference: ISO12100/JISB9700 6.2.6)

Machines must be designed in ways that they have sufficient stability and can be used safely

under specified use conditions.
Examples of Factors to be Considered

● Basic geometry dimension

● Weight distribution including load

● Dynamic force due to moves of machine components that cause overturning moment, machines themselves,
and elements attached to machines

● Vibration

● Center of gravity fluctuation

● Characteristics of traveling road surface or installation surface at various sites (land conditions, gradients,
etc.)

● External force such as wind pressure and human power

Machine stability needs to be considered in all lifecycle phases from handling, transportation, installation, use,
disassembly to disposal.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-5. Provisions for Stability (Reference: ISO12100/JISB9700 6.2.6)

Which is stable?

Stable・・・a condition in which the object tries to When the center of gravity is high, a
return to the original position. slight tilt could lead the object to fall.

Center of Gravity Stable design
・low machines
・Heavy objects should be installed at
low positions, etc.

falling fulcrum

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-5. Provisions for Stability (Reference: ISO12100/JISB9700 6.2.6)

Example of Foundation Drawing

基礎図（出展 据付施工と初期保全より）

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-6. Provisions for Maintainability (Reference: ISO12100/JISB9700 6.2.7)

When designing a machine, the following maintainability must be considered in order to enable

maintenance.

・Accessibility: Consider human body dimension including environment, work clothes and dimensions of
tools used
e.g. Putting tools in a narrow space could cause an unreasonable work posture.

・Handling Ease (Pay attention to human ability.)
e.g. Heavy, hard to transfer or replace → Leading to an unreasonable work posture

・Limits to the number of special tools and equipment
e.g. Explosion-proof tools and measures for a lack of oxygen

Explosion-proof Safety Tools
Tools that don’t cause sparks when
friction or impacts are applied to
them.
Material: beryllium copper

Explosion-proof Tools (Shirai Co., Ltd. Website)
http://shirai-co.com/bobakukogu.html）

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-7. Observing Ergonomic Principles (Reference: ISO12100/JISB9700 6.2.8)

Ergonomics principles must be considered at the design phase in order to alleviate the operator’s mental

or physical stress and tension.

Note: This would lead to enhancing the operational performance and reliability, and reducing the possibility
of misuse in all operational phases.

a) Make sure to eliminate stressful work actions and postures during machine operation

e.g. Work height and positions should be adjustable depending on each operator. b) Design

handy and movable machines in particular in ways that the operators can use them easily in terms of

work efforts, control device operation, and physical structures including arms, hands and legs

e.g. Heavy, switch location, etc.

c) Minimize the impact of noise, vibration, and heat such as extremely high temperature.

d) Do not try to align the operator’s work rhythm to the machine’s automatic running cycle.

e) Install lighting for the machines set at a place that lacks proper lighting due to the design

characteristics of themselves or their guards. The impact of flash, glare, shadow and stroboscopic effect must

be avoided if they could cause risks.

e.g. Image processing light source and visual check lighting, etc.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-7. Observing Ergonomic Principles (Reference: ISO12100/JISB9700 6.2.8)

Easy to Work Posture

Safety Standard for Machinery S-08-001 “Work Environment Standards”

Physique differs from
person to person.

↓
Fatigue level decreased
thanks to adjustments

Noise

Safety Standard for Machinery S-08-001 “Work Environment Standards”

Determination of control class based on measurement reults of equivalent noise level Action based on control class

Machinery improvement measure etc Other measures etc.

Less than 85dB 85dB or more and 90dB or more First control Maintain current control status Nothing particular
less than 90dB
Second Take measures to move to first Thoroughly ensure

A Average Measurement val 80bB or more and les s First cotrol clas s Second control Third control class control class control class wearing of
than 85dB clas s
Third control Can be dangerous to health so take protective gear until

class immediate moved

85dB or moe and less Second control Second control Third control class There are currently no effective measures for rubber kneading plosive noise
than 90bB clas s clas s
or burner flame noise, so take action by wearing protective gear

90dB or more Third control class Third control class Third control class Rough 90db growl
indication for 80db loud voice
Safety and health regulations and the Noise Damage Prevention Guideline shall be noise levels 70db normal conversation
applied to the measurement methods and standards.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-7. Observing Ergonomic Principles (Reference: ISO12100/JISB9700 6.2.8)

High Temperature Environment Image: Heat Stroke WBGT Meter
(Sato Keiryouki MFG. Website)
Work intensity Allowable Temperature https://www.sksato.co.jp/modules/shop/product_info.php?cPat
Very Light Work（RMR≦1) Criteria h=24_34&products_id=862）

（WBGT ℃）

32.5

Light Work (1＜RMR≦2) 30.5

Moderate Work (2＜RMR≦3) 29.0

Moderate Work (3＜RMR≦4) 27.5

Heavy Work (4＜RMR≦53) 26.5

RMR (relative metabolic rate）
Ratio of energy consumed to the basal metabolic expenditure

WBGT (wet bulb globe temperature)
Indicator to prevent heat stroke focusing on the heat transfer between the human
body and the ambient air

Illuminance (Excerpt from JIS Z9110:2010) Example of the Work Table
Equipped with Fluorescent Lamp
Work Maintenance Illuminance
（lx） Illuminance
Extremely detailed visual work at precision machines, electronic device
production or printing factories, etc. 1,500
Detailed visual work such as inspections at textile factories and analysis at
chemical plants 750
Normal visual work at general manufacturing factories
500
Coarse visual work such as wrapping and packing 200
150
Stairs 100

Corridors, aisles and entrance/exit

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-7. Observing Ergonomic Principles (Reference: ISO12100/JISB9700 6.2.8)

f) The following is about the selection and identification of Manual Control Device (actuators).

・Should be clear, visible, and identifiable, and properly displayed when needed.
・Should be safely operable and quickly without hesitation and ambiguity.

e.g. Positions and arrangement of devices on the control panel should be unified (to prevent erroneous operations)

・Positions and behaviors of a manual control device should coincide with the results of the operations.

e.g. A device should ascend when its lever is raised.
・Operating a manual control device shouldn’t bring any additional risks.
When a manual control device is designed to execute multiple different behaviors, such behaviors must be clearly indicated and
confirmable when needed.
Manual control devices must be arranged in consideration of ergonomics in order to coincide their positions, travel distance and
resistance force with intended operations. When protective gear (shoes and gloves, etc.) are predictably needed, take into
account possible restrictions caused by such gear.

e.g. Pressing a switch with the gloved hand could also press another switch next to it.→Secure a certain distance between
switches.

g) The following is about the selection, design and arrangement of indicators, dials and visual display units
・They should fit the human’s sensory parameters and characteristics.
・Information displayed on these devices must be easily noticeable and identifiable.
・The operator should be able to recognize their conditions at the operating position.

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5-2-7. Observing Ergonomic Principles (Refer to ISO12100/JISB9700,6.2.8)

The table below indicates visual effects for easy recognition.

Table: Application of ergonomics to visual indicator (source: International Safety Standard 2 (2007) by Masao Uchidono, p. 106)

Recognizability of shapes Recognizability of letters Impression of colors

Ranking Shape Character Comparison Color Perception Applicability
Triangle
1 Diamond Kanji 0.6 Red Strong stimulus, danger Stop, error
2 Square Hiragana 0.9
3 Rectangle Katakana 1 Green Secure, safe Go ahead, safe
4 Pentagon Alphabet 1.2
5 Circle ＡＢＣ Blue Calmness, rest Normal
6 Hexagon Yellow/black Prominent when used in combination
7 Necessity of
care

5. Inherently Safe Design Measures P56/135

5-2-7. Observing Ergonomic Principles Sumitomo Riko Group

(Refer to ISO12100/JISB9700, 6.2.8)

When reduced, the triangle is most distinguishable of
them all.

危険 きけん キケン

Kanji Hiragana Katakana

Which type of character is most recognizable?

P57/135

5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-8. Electrical Hazards (Refer to ISO12100/JISB9700, 6.2.9)

There’s no provision for the design of machine’s electrical devices in ISO12100/JIS B9700.

Regarding electrical safety, refer to the requirements for disconnection/opening/closing of circuit and

protection against electrical shock specified in IEC60204-1/JIS B9960-1 .

Electric shock is caused Direct contact: Touching parts to which voltage is usually applied
by touching live parts
Indirect contact: Touching a live part, which is usually insulated, exposed due
to dielectric breakdown.

Table: Protection against direct contact (source: International Safety Standard 2 (2007) by Masao Uchidono, p. 107)

Classification Safeguard Requirements
(1) Conductors inside enclosure : At least IP2X or IPXXD
En clo s u re
(2) Enclosure upper surface: At least IP4X or IPXXD
In s u lato r
Direct contact (3) In case personnel approach live parts opening the enclosure with the inner devices energized
-Conductors inside: At least IP1X or IPXXA
Barrier -Conductors which will be set or adjusted with the device connected to the power source: At least IP2X or IPXXB
Ob s tacle (4) Parts continually charged after circuit is opened: At least IP2X or IPXXB (post warning sign)
Protection against (5) conductors approachable by opening the enclosure without the key/tool or without disconnecting live parts: IP2X
residual voltage or IPXXB
Cover with insulating material that cannot be removed without breaking.

(1) In front of energized parts, install the barrier which can be only removed with the key or tool.

(2) Structure to enable removal only after cutting off the power to live parts that may cause electric shock or enable
power supply only after the barrier is replaced.
(3) In case easily accessible, barrier shall have protection rating of IP4X at minimum.

Fix securely so that personnel won't remove it unconsciously, whether or not keys or tools are necessary.

60V or higher residual voltage must be lowered to less than 60V in 5 seconds after power disconnection. If
discharging within 5 seconds is impossible due to adverse effects on the device, electrical shock warning sign must
be posted near or on the enclosure of the applicable part.
Conductor exposed when plug is pulled out shall discharge within 1 second and have the protection rating of IP2X or
IPXXB.

P58/135

5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-8. Electrical Hazards (Refer to ISO12100/JISB9700, 6.2.9)
IP（International Protection ）
②③
①

Control box (example)

Protection rating (IP indication)(source:Welltech Instrument Co. Ltd (http://temperature-humidity-chamber.com/explosionproof.html ）

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-8. Electrical Hazards (Refer to ISO12100/JISB9700, 6.2.9)
Prevention of access to live parts

Turning the handle turn
off the breaker

Breaker handle: Control panel will open only when power is disconnected. → To
prevent personnel from approaching live parts.

To prevent personnel from Terminal block Plug-in type terminal
approaching live parts: cover

Energized parts inside
the panel → Cover with
terminal cover or other
proper apparatus

Breaker terminal cover（Fuji Electric website, Terminal block（Toyogikenn website, HP http://www.togi.co.jp/products/details.php?main=terminalblock&sub=rail-install%20spring-lock&c=221）
https://felib.fujielectric.co.jp/docfetch/CustomContentDownload.aspx?sid=BC83A413476FF859F0078

5B069A525EA1EA5299D52EE3557&dataid=5625660&version=0&site=japan&lang=ja）

P60/135

5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-8. Electrical Hazards (Refer to ISO12100/JISB9700, 6.2.9)

Table: Protection against indirect contact (source: International Safety Standard 2 (2007) by Masao Uchidono, p. 108)

Clas s ificatio n M eas u re Requirements

Indirect (1) Use of class II devices
Class II devices are defined as those provided with:
contact: Prevention of ① Basic insulation as an element of fundamental protective means; and
Personnel or contact voltage ② Auxiliary insulation as an element of protective means against failure; or
livestock may generation ③ Reinforced insulation for fundamental and failure protection.
touch (2) Insulation equivalent to class II devices
① Use switching and control devices provided with entire insulation conforming to IEC60439-1
exp o s ed ② Use additional or reinforced insulation conforming to IEC60364-4-41, Section 413.2.
(3) Electrical isolation
conductive ① Power supply from the insulating transformer or other sources of equivalent safety class
② 500V or lower voltage
part energized ③ Flexible cable or cord susceptible to mechanical damages can be visually checked.
④ No circuit has live parts that may come in contact with other circuits (refer to the requirement described in Section
due to trouble 413.5 of IEC60364-4-41)
(1) Exposed conductive parts shall be connected to protective bonding circuit.
(fault) (2) Either ① or ② shall be employed.
① TN or TT system shall use protective device that automatically shut off power in case of insulation failure. (TT
Protection by system, employed in Japan, automatically shuts off power.)
automatic shutoff ② IT system shall be provided with electric leak detector or earth leakage breaker that automatically shuts off power.
of power (1) Nominal voltage
① Use at dry environment: AC25V （effective value）/DC60V（without ripple） when contact between human body and
Indirect Use of PELV live part does not extend to large area
contact and ② Others: AC6V（effective value）/DC15V（without ripple）
direct contact (2) Either side of the circuit or one point of circuit power supply shall be connected to the protective bonding circuit
at limited area (3) PELV circuit's live parts shall be electrically isolated from other energized circuits.
(4) PELV circuit conductor shall be isolated from other circuits.
(5) Plugs shall be able to be inserted to the applicable electric system only.

P61/135

5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-8. Electrical Hazards (Refer to ISO12100/JISB9700, 6.2.9)

Indirect contact →Leaking current gives electric shock

Fatality rate is high depending on voltage, duration/route of current flowing through the body, type of current (AC is 4

to 5 times more hazardous than DC) and physical condition.

Resistance of human body:

A.C. Reaction of body Dry body: About 4,000Ω
0.5 mA No reaction Wet body: About 2,000Ω

1 mA Shock is felt Current that flows through the body
5 mA Tremendous hurt is felt
10-20 mA Muscular stiffening if 100V live wire comes in contact 100V is
50 mA Highly hazardous (lethal) 15mA - with the body
hazardous
Muscles “freeze” Dry body: 25 mA enough！

Illustration: Electric shock Wet body: 50 mA
（source: Kanto Electrical Safety Services Foundation
website,https://www.kdh.or.jp/safe/document/basic/short.html）

To prevent contact with current

Appliance class II → Protection through double insulation Insulation
or enhanced insulation

図 二重絶縁（引用 関西電気保安協会HP www.ksdh.or.jp/pages/wp-content/uploads/.../materials_ws_office_1.pdf ）

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5-2-8. Electrical Hazards (Refer to ISO12100/JISB9700, 6.2.9)

Protection by automatic power shutoff (both grounding and protective device)

Earth leakage Not grounded:
Dielectric breakdown won’t be found till
touching→Electric shock

Leaking current Grounding Grounded:
Leaking current will go to earth and
leakage is detected →Safe

Illustration: Protection against electric shock（Source:https://www.kdh.or.jp/safe/document/knowledge/construction03.html）

Example of grounding Earth leakage circuit breaker High current
Long exposure to
Illustration: Protective bonding Sensed electric shock
｛Japan Machinery Federation, International standard for machine safety, IDEC publication（2012） current
High fatality rate
www.jmf.or.jp/japanese/standard/pdf/M_5.pdf ｝ Operation
time Sensed current: 30 mA
Operation time: 0.1 s at max.

Source: Machine Safety
Standard S-01-001, “Automatic
Breaker”

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-8. Electrical Hazards (Refer to ISO12100/JISB9700, 6.2.9)

PELV（protected extra low voltage） Protection against shock
Lowering the voltage
Mortality risk of electric shock

High voltage (current flowing through the body is high)→ Dangerous
Low voltage (current flowing through the body is low) → Safe

ISO/IEC specifies the following PELV for protection Control power of 24V is used.

AC DC

Use in dry environment 25V 60V
6V
Human hody area contacting with 15V
live parts is expected small

Cases other than the above

Illustration: Power supply（source: http://www.fa.omron.co.jp/product/special/ps/）

Mortality risk of electric shock 42V is sometimes called a deadly voltage in Japan, as “4” is
ＤＣ ＜ ＡＣ also pronounced “shi” meaning “death” in Japanese. “42V” can
be read as “shi ni volt” meaning “voltage inducing death.”
Alternating current is said to have 4 to 5 times
higher risk than direct current (effect on heart)

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-9. Pneumatic and Hydraulic Hazards (Refer to ISO12100/JISB9700, 6.2.10)

It is stipulated as follows for designing of pneumatic and hydraulic devices for machinery.

・The maximum pressure rating of the circuit shall not be exceeded (safety valve, relief valves, etc.).

・ Hazards shall not be generated from pressure fluctuation/increase or loss of pressure/vacuum.

・ Leakage or component failure shall not cause hazardous fluid to blow out or hose to make abrupt
dangerous motion.

・Air receiver, air tanks or similar containers (e.g. accumulator filled with gas) shall conform to the
Design Standards or applicable laws and regulations.

・All the device members, especially pipe and hose, shall be protected from hazardous external influences.

・Tanks and similar containers shall be automatically depressurized as far as possible when the machine
power is cut off. If it is not possible, provide the means for shutoff, local depressurization and pressure
indication.

・All the members maintaining pressure after power cutoff shall be provided with clearly identifiable
discharging devices with warning label attached to inform personnel of the necessity of depressurization
for these members.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-9. Pneumatic and Hydraulic Hazards (Refer to ISO12100/JISB9700, 6.2.10)

Safety valve: hydraulic circuit

Safety valve (mainly for gas and steam)
Installation on boilers and pressure vessels are required by
law.

Relief valve (mainly for fluid)
As to the hydraulic circuit, place on the secondary side of
the pump. The circuit pressure shall not exceed the set value.

Residual pressure relief valve:

Manual switching valve to prevent accidents caused by
residual pressure

Residual pressure relief valve（source: SMC website, http://www.smcworld.com/catalog/BEST-old-
jp/pdf/vhs.pdf#page=1）

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5-2-9. Pneumatic and Hydraulic Hazards (Refer to ISO12100/JISB9700, 6.2.10)

Pressure vessels are strictly controlled by the applicable Japanese laws
concerning manufacture, installation and inspection.

Because they accompany high risk once accidents happen.

Excerpt from the Order for Enforcement of the Industrial Safety and Health Act Classification depending on the maximum pressure applied and inner volume
（source: Japan Boiler Association website:
Class 1 pressure vessel: Vessels as illustrated on the right
・Vessel for containing heat medium such as steam, generating steam to heat solid http://www.jbanet.or.jp/examination/classification/vessel_1.html）
or liquid (vessel inner pressure is the same or higher than the atmospheric pressure)
or others.

Auto Clave Machine : Equipment for curing rubber hose with the steam at around 0.5MPa Classification depending on barrel ID and length
（Maximum pressure used≦0.1MPa）

（ (source: Japan Boiler Association website: http://www.jbanet.or.jp/examination/classification/vessel_1.html）

Japanese only

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-9. Pneumatic and Hydraulic Hazards (Refer to ISO12100/JISB9700, 6.2.10)

Excerpt from the Order for Enforcement of the Industrial Safety and Health Act

Class 2 pressure vessel:
Vessels containing 0.2 MPa or higher gas that have:
・Inner volume of 0.04m3 or larger
・Barrel whose inner diameter and length are at least 200 mm and 1000 mm
respectively

Classification depending on the maximum pressure applied and inner volume
（source: Japan Boiler Association website:

http://www.jbanet.or.jp/examination/classification/vessel_1.html）

Receiver tank Dehumidifier system Classification depending on barrel ID and length
(source: Japan Boiler Association website:

http://www.jbanet.or.jp/examination/classification/vessel_1.html）

Japanese only

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-10. Applying Inherently Safe Design Measures to Control Systems
（Refer to ISO12100/JISB9700, 6.2.11)

To reduce risk arising from inadequate design of Control System, fault of component, unexpected activation
of machine or others, the following items shall be considered in design. Detailed explanation for each item
will be provided in later sections.

① General
② Starting of an internal power source/switching on an external power supply
③ Starting/stopping of a mechanism
④ Restart after power interruption
⑤ Interruption of power supply
⑥ Use of automatic monitoring
⑦ Safety functions implemented by programmable electronic control systems
⑧ Principles relating to manual control
⑨ Control mode for setting, teaching, process changeover, fault-finding, cleaning of maintenance
⑩ Selection of control and operating mode
⑪ Applying measure to achieve electromagnetic compatibility (EMC)
⑫ Provision of diagnostic systems to aid fault-finding

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-10-1. Applying Inherently Safe Design Measures to Control Systems –General
（Refer to ISO12100/JISB9700, 6.2.11)

General conditions
① At least one of the following solutions shall be considered for an operator to interact with the machine safely
and easily.

・Systematic analysis of starting and stopping conditions
・Definition of specific operation mode (e.g. activation after normal stop, restart after emergency stop)

・Clear posting of fault (trouble) information
・Means to prevent issuance of unexpected incidental start command that may cause machine to make hazardous

behavior (e.g. covering starting button)

・Stop command maintained to prevent restarts that may cause the machine to make hazardous behavior (e.g.

interlock)

②In-line machines may be divided into some zones corresponding to emergency stopping, and feature stoppage by
means of protective devices. In those cases boundaries between zones shall be defined to clarify which machine belongs
to which zone (e.g. hazard check sheet, tower light)

In the same way, clarify the zone each control (emergency stop, power breaker)/protective device belongs to.
Zone-to-zone interfaces shall be designed so that the functions of each zone won’t cause hazards to the zones stopped for
intervention.
③ Control systems shall be designed to restrict the machine itself, work piece and/or motion of the load held by the machine
within the safe design parameters (e.g. range, speed).

Example: Travel speed of moving machines controlled by personnel walking shall match their walking speed.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-10-1. Applying Inherently Safe Design Measures to Control Systems –General
（Refer to ISO12100/JISB9700, 6.2.11)

Definition of specific operation mode

Restart after emergency stop

Emergency stop Cancellation of emergency stop Operation ready Restart

Refer to the Standard for Emergency Stop & Emergency Stop Switch

Prevention of restart that may cause the machine to make hazardous behavior

Means to prevent personnel from being trapped in the

machine
Inner reset button (①)to escape out of the machine(②)

Example of pre-reset (inner reset （source: OMRON website To restart, external reset button(③) must be
http://www.ia.omron.com/Images/3403_fe_1713-229678.jpg/） pressed.

(The pressing of this button by a third party may not
activate the machine.)

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-10-2. Applying Inherently Safe Design Measures to Control Systems -Starting of an internal
power source/switching on an external power supply
(Refer to ISO12100/JISB9700, 6.2.11.2)

Provided as follows concerning the inner power source activation or connection to external power supply.

Activation of inner power source or connection to external power supply shall not cause hazardous situation

Example: Starting the internal combustion engine shall not make movable machines travel (e.g. automobile engine)
Connection to main power supply shall not activate the machine moving parts.

Switch Warning :
Avoid accidental starting. Ensure the switch is in the off position
before plugging in.
Carrying power tools with your finger on the switch or plugging in
power tools that have the switch on invites accidents

Disk grinder operation manual（source: Hitachi Kogyo website, http://www.hitachi-koki.co.jp/manual_view_domestic/pdf/C99205403_G10SH5_400.pdf）

5-2-10-3. Applying Inherently Safe Design Measure to Control Systems -
Starting/stopping of a mechanism (Refer to ISO12100/JISB9700, 6.2.11.3)

6P.2ro.1v1id.3ed参a照s fo）llows concerning machine start and stop.
Start/acceleration of mechanism: It is preferable to apply or increase voltage or fluid pressure, or raise energy

Stop/deceleration of mechanism: It is preferable to remove or reduce voltage or fluid pressure, or lower energy

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-10-4. Applying Inherently Safe Design Measures to Control Systems -Restart after power

interruption (Refer to ISO12100/JISB9700, 6.2.11.4)

Provided as follows concerning restart after power interruption. If re-

excitation after power interruption may automatically reactivate the machine, causing hazard, such

reactivation shall be prevented.

Example: Employment of self-holding relay, electromagnetic contactor or valve

Holding circuit: Ｐ２４ Ｎ Pushbutton Pushbutton Ｐ２４
Ｎ Toggle switch switch switch
ＣＲ

ＣＲ ＣＲ

ＣＲ ＣＲ

Ｍ Ｍ

Switch remains on when power is recovered. Pushbutton switch and self-holding relay is cut off.

Injury due to unexpected motion No activation if power is recovered.

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5. Inherently Safe Design Measures Sumitomo Riko Group

5-2-10-5. Applying Inherently Safe Design Measures to Control Systems -Interruption of power

supply (refer to ISO12100/JISB9700, 6.2.11.5)

Provided as follows concerning interruption of power supply.

The machine shall be designed to prevent hazardous condition that may be caused by interruption or excessive
fluctuation of power supply.
Indicated below are minimum requirements to follow.

・Machine stopping function must be always active.

・All the equipment required to be constantly in operation for safety reasons shall operate in an effective
manner to ensure safety (e.g. locking/clamping device, cooling/heating device).

・Works/loads with potential energy held by a member of the machine or movable machine shall be held until
they are moved to the safe position.

In case of elevators: Power
Battery is required to run till the elevator car failure
arrives at the nearest floor.
停電時継続運転機能（東芝エレベータ株式会社HP http://www.toshiba-elevator.co.jp/elv/new/elevator/option/tosmove_neo.html）

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5-2-10-6. Applying Inherently Safe Design Measures to Control Systems - Use of automatic

monitoring (Refer to ISO12100/JISB9700, 6.2.11.6)

Provided as follows concerning automatic monitoring.

Automatic monitoring shall be used to immediately detect or regularly check faults for the purpose of detecting
faults (trouble) before the safety function is required to operate. In either case, protective measures will be
started at once or delayed until a specific event occurs.

Example of automatic monitoring Japanese only

Small fire in October, 2013: Local part was heated due to fan Automatic monitoring by means of light curtain（OMRON website www.fa.omron.co.jp/product/sf_back/sf_back_pdf/safety-
stoppage. digest.pdf ）

Machine Safety Standard “Malfunction of fan for electrically heated air- Depending on machine types, repeat switching ON and
heating furnace, fire prevention” OFF at 80ms intervals.
OFF signal undetected → Undetectable by men
Sensor detected the fault.
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