Robot Risk Assessments are Not Created Equal
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June 30, 2022 - As supply chain challenges and workforce shortages continue to affect most industries, automation is taking place at a global scale and accelerating. More than 50,000 warehouses worldwide are expected to include commercial robotics by 2025: a dramatic jump from the only 4,000 documented in 2018. The industrial robots market growth is at a record rate of nearly 20 percent per annum since 2012 and is expected to continue in double-digit growth well into this decade.
Advances in both collaborative robots and autonomous mobile robots (AMRs) have allowed this technology to became more functional and readily available across a wide range of work environments, however they each present a unique set of health and safety challenges.
Collaborative Robots are purposely designed to work in the same operating space as humans. The robot system and humans collaboratively perform concurrent tasks within a shared workspace during production operations. This is different from traditional conventional robots, which cannot safely operate around people. Found in research facilities, warehouses, manufacturing facilities, hospitals, and retail chains, these collaborative robotic systems are desirable because of their flexibility of use, ease of integration and programming, and integrated safety features.
Some of the risks associated with collaborative robots include:
• Strikes
• Pinches/entrapment
• Entanglement (cables)
• Drop/throw objects
• Automatic/remote start up
• Power and speed
• Stopping distance
AMRs are self-navigating, self-pathing mobile platforms that can move materials and products between multiple locations without human intervention. They are quickly replacing automated guided vehicles (AGVs), which must follow predetermined marked paths. AMRs use a combination of sophisticated sensors and cameras to detect obstacles and prevent collisions. They are able to re-path to move around obstacles in a dynamic environment. An AMR for instance can learn the layout of a 200,000 square foot facility in just a matter of hours and can easily maneuver around its footprint, avoiding unexpected obstacles, and moving or loading items according to current needs.
Additionally, an AMR can have a collaborative robot arm attached to it. This is known as an AMR Type C. This combination greatly increases the flexibility and utility of the system, and can allow more complex tasks such as machine tending of multiple machines.
Despite their integrated safety features, collaborative robots and AMRs may still pose a risk of injury to workers. It is often taken for granted that they are completely safe because they are designed to work alongside humans. These assumptions lead to less monitoring, upkeep, and EHS involvement once the robot has been integrated. However, they present unique hazards that require additional and specific knowledge for safety professionals that goes beyond standard risk assessment practices, especially when evaluating the interactions between robots and humans. The use of these robotics systems requires a documented risk assessment, which includes identification and evaluation of all planned and unplanned human interaction and the work environment.
Workplace safety and health continues to evolve, presenting safety professionals with challenges and opportunities. BSI Senior Consultant Daniel Chodos and BSI Principal Consultant Mollie Anderson, presented this topic at ASSP’s Safety 2022 conference on June 27 in Chicago.
