Use of robots in automated processes - What are the safety implications?

Automation of processes is preferred by most of the organizations as it reduces human interface and improves productivity. In manufacturing / engineering industry, auto sector, etc most of the material handling jobs are automated and robots are engaged for complex jobs. This reduces lifting of weights of human beings, avoids stress / strain caused due to repetitive jobs and thus reduces health care costs.

However, it is important to understand the programming that went into sequencing of operations to be done in automated jobs and its implications particularly when the jobs are partly automated, partly manual. The job may look simple when routine sequence of operations are carried out. However, if any interruptions / change of sequence is there or breakdown occurs or power failure takes place, we need to know its impact on operations. May be we did not thought of restricting the functioning of robots or like it happens in computers when power failure occurs, there may be hanging of the computer programme. Whether such a situation creates any hazard to shopfloor operators in the vicinity is to be assessed.

Or, what are the hazards when maintenance is to be done when these automated systems are in energized condition. Whether safe positioning is incorporated when emergency stop switch is operated is to be known. Else, when someone looks into the problem during a breakdown, any of his repair job may cause the robot arm to move and hit the maintenance engineer.

Before programming the logics, a detailed WHAT IF analysis is to be done by involving concerned including design engineer, operation engineer, instrument engineer, maintenance engineer, safety engineer, etc to assess all possible hazards for all regular operations / breakdown jobs / maintenance, etc.

Still, there may be surprises depending upon the extent of questioning, imagination, thinking is put during hazard evaluation.