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Equipment failures and their contribution to industrial incidents and accidents in the manufacturing industry

Bourassa D., Gauthier F., Abdul-Nour G.

International Journal of Occupational Safety and Ergonomics

2016

Vol. 22, No. 1

131--141

Accidental events in manufacturing industries can be caused by many factors, including work methods, lack of training, equipment design, maintenance and reliability. This study is aimed at determining the contribution of failures of commonly used industrial equipment, such as machines, tools and material handling equipment, to the chain of causality of industrial accidents and incidents. Based on a case study which aimed at the analysis of an existing pulp and paper company's accident database, this paper examines the number, type and gravity of the failures involved in these events and their causes. Results from this study show that equipment failures had a major effect on the number and severity of accidents accounted for in the database: 272 out of 773 accidental events were related to equipment failure, where 13 of them had direct human consequences. Failures that contributed directly or indirectly to these events are analyzed.

Przekrawacz rotacyjny do produkcji kartonu - dokładność cięcia

Musielak S.

Przegląd Papierniczy

2011

R. 67, nr 9

564-568

W artykule przedstawiono problematykę dokładności cięcia na tekturnicy, w której wiodącą rolę odgrywa przekrawacz rotacyjny. Wymagania klientów dotyczące dokładności cięcia przekrawacza rotacyjnego wciąż rosną, a wymagania stawiane obecnie układom regulacyjnym pod względem właściwości dynamicznych w procesie są coraz wyższe. Dokładność cięcia jest jednym z ważniejszych wskaźników technologicznych dla klientów posiadających te maszyny i odbiorców tektury. Dochodzi bowiem do sytuacji, gdy producent na wskutek złej jakości kartonu, zbyt dużych odchyłek od tolerancji cięcia traci klientów i to nieraz bezpowrotnie! Na rynku tekturnic panuje ostra walka konkurencyjna: duże spółki oraz małe firmy rodzinne. Ciągle zmieniające się warunki na rynkach tektury wymagają prowadzenia procesu technologicznego niezawodnie i dokładnie. Tekturnica (1) jest obiektem złożonym i drogim, pracującym z reguły w systemie 3-zmianowym, a postoje i zakłócenia procesu są niewskazane.

In the corrugated process, the original material is the corrugated board. In the final phase of the production, the board is cut to a certain format. This is the last phase in corrugated board production with the cutoff in the leading role. The cutting accuracy is among the major features of the cutoff. The final result of the product and the success of the board manufacturer depend on cut, cutting accuracy and on the technological "look" of the cut off board. The presentation compares two knife systems, the encoder application as a classical measurement concept and a laser application as alternative. How large are the standard deviations of the cutting process? What is the main fault cause? The major factors for negative influence on the cutoff control system are: the influence ot speed of the corrugator line and the technological process per se. The article describes the results of the research work performed on cutoffs. Growing requirements on cutting accuracy and the target to achieve a high frequency of the board cut within an order are among the most relevant criteria as to state-of-the-art cutoffs in the technological corrugator system. The author presents frequent system errors for both measurement methods in industry. An analysis of their advantages and disadvantages is available. The cutting allowance was defined, as well as the difference for the cutoff systems "Simplex", "Duplex" and "Triplex". The cutoff, type "Triplex", is becoming more frequent, and this is where problems as to cutting differences may occur - particularly in cases concerning the work of the complete module, i.e. the work of all three modules. Results relating to the German company Polytec, who are among the worldwide leading companies in this category, are presented. Examples of inconsistent processes are given and proposals for optimization by stabilization of the culling process with laser application in daily industrial routine are made. Moreover, the laser system as outstanding alternative to service and diagnostics is discussed. Target of this presentation is to introduce new corrugator customers to the alternative measurement method and the introduction of new application possibilities of the laser as to the corrugator, and not only in terms of latest state-of-the-art machines. Likewise the reduction of production costs and complaints is to be considered.