A risk assessment of human-robot interface operations to control the potential of injuries/losses at XYZ manufacturing company

Abstract

The purpose of this study was to assess the robot palletizing operation at XYZ Manufacturing Company using the risk assessment methodology recommended by the ANSI/RIA R15.06 standard. XYZ Manufacturing Company is a food processing company located on the Midwest, U.S. Just two years ago they installed five industrial robots, automating a significant part of their packaging operations. Since then risk assessments of the operation have not been performed. The lack of robot operations assessment is placing employees at risk of injuries. Even though XYZ Manufacturing Company had not had any accidents, there is a great potential of occurrence within the operation. Data on robot-related accidents is difficult to find, nevertheless studies have reported accidents in France, Sweden, Japan, and USA, including fatalities (Beauchamp & Stobbe, 1995). There have been five fatal accidents involving industrial robots since 1978 (Dhillon, 1991). In order to control these accidents and reduce losses, standards have been developed as well as recommendations of preferred practices, including the American National Standards Institute (ANSI), the National Institute of Occupational Safety and Health (NIOSH), the Department of Energy (DEO), and the Occupational Safety and Health Administration (OSHA). This study utilized several of these standards and guidelines in developing its approach and providing recommendations. The robot palletizing operation at XYZ Manufacturing Company was assessed considering employees’ previous experiences, current procedures and practices, and human factors. Identification and analysis of hazards inside and outside the work cell was provided through the ANSI/RIA Risk Assessment. The results of the study identified various deficiencies or areas of opportunity in the palletizing operation. Recommendations to these situations at XYZ Manufacturing Company were presented. Moreover, the methodology utilized on this study provides a guideline to perform further analysis in existent and new operations.