Robotics safety in the workplace

Find out what your business can do to minimize the hazards involved with using robotic machinery.

An increase in production is often associated with an increase in robotic use. This may include traditional industrial robots that operate in isolated work cells, collaborative robots (cobots), autonomous mobile robots and other robotic technologies that operate near or alongside workers.

While robots can take away burdensome manual tasks, they often do this with great speed and force which may increase the risk of serious injuries or death to workers.¹ A NIOSH (National Institute for Occupational Safety and Health) study found 61 robot-related deaths between 1992-2015.²

Newer robots may be “safer” with presence sensors to cut power if they detect a person in the work environment. Unfortunately, even with better safeguards the growing use of robot technology and the increased density of robots in the workforce creates a greater risk of struck-by injuries, crush injuries, pinch-point injuries, and human-machine interface errors.  This is especially true during maintenance, programming, troubleshooting, and unexpected startup events.

As an employer you have the responsibility to provide your employees with a workplace that is free from recognized hazards that are likely to cause death or serious physical harm to employees. 

Ensuring a safe workplace is not only the law in the U.S., but also good business.

So, what should you do? Here are three steps to help you use robotics more safely:

1. Complete a risk assessment

Assessment must be based upon a standard. The original equipment manufacturer (OEM) will be the first place to go. Read the user and maintenance manuals by the OEM and comply with them.

Federal OSHA General Duty Clause, General Machine Operations, Energy Control (lockout/tagout), Energy Transmission, and others should be included as minimum standards for the assessment.

2. Provide orientation and performance training

Orientation and performance level training relevant to the situation should occur.

The performance piece applies to operators, people working in or near robotic equipment, and those who service and maintain it. Never allow untrained personnel anywhere near the robots’ hazard zone(s).

Confirm that injury exposures, controls, and protective equipment specified in OEM guideline(s) and all applicable legal requirements are understood and followed.

3. Audit work and learn from events

Remember the maxim, “What gets measured gets done. But what is measured regularly is done regularly.” Periodic and scheduled audits should be performed. Findings, near misses and losses should be used to strengthen safe work practices.

Appropriate praise or work redirection must occur if audits are to reinforce safe work practices.

In addition to these steps, Nationwide’s Every STEP Counts program can help build a structured, measurable worker-safety process. The program is organized around four key principles: Selection and orientation; Training and safety programs; Events and loss response; and Post-event understanding and actions. These principles can complement robotics-specific risk assessment, training and auditing by helping employers prevent incidents, respond when events occur and learn from them. The program can be used where needed rather than in a specific order.