This audio was created using Microsoft Azure Speech Services
When it comes to safety systems, we’ve come a long way. About a century ago, workplace accident rates were alarmingly high, particularly in mining, with an average annual accident rate of 329 per 100,000 workers. The introduction of the safety instrumented system, real-time monitoring, and OSHA regulations drastically reduced these rates, which today have improved to 3.7 per 100,000 workers.
While it’s great progress, it also underscores the importance of continued innovation and vigilance. Safety, as the saying goes, is as much about the journey as the destination — the goal is zero accidents. Factory floors are dynamic workplaces, and every worker should return home safely.
As we look ahead, the next generation of safety systems must be versatile, resilient, and capable of meeting the needs of modern industries for the next three decades. Let’s examine how digital readiness and adaptability transform industrial safety and how future-proof systems must be designed for continuous improvement.
Adapting to complexity: the evolution of industrial safety systems
Industrial safety once relied heavily on mechanical devices and manual oversight, all prone to human error and equipment failure. The mid-20th century saw the introduction of basic electronic controls and hard-wired safety circuits, marking the beginning of safety system automation. By the late 20th century, digital programmable logic controllers (PLCs) and safety instrumented system (SIS) allowed for more complex logic and reliable safety functions.
While effective, these systems were often rigid and unable to adapt to the rapidly changing industrial landscape. As industries adopted more sophisticated technologies, flexibility and real-time adaptability became critical factors, from system design to implementation.
Bridging the 30-year workforce and technology gap
Today, there is a significant generational shift, with experienced professionals retiring and digital natives entering the workforce. Safety systems must be designed to be intuitive for the newer workforce and seasoned experts alike. Flexibility and scalability enable these systems to adapt to evolving standards and integrate new technologies without extensive retraining.
Digital natives prefer user-friendly interfaces and automated process systems that:
- Simplify complex tasks and provide clear, actionable data
- Improve operational efficiency
- Help bridge generational knowledge gaps
It’s important that these systems support new business strategies and sustainable methodologies like biofuels and increased electrification while also providing the flexibility and scalability needed for future-proof safety architectures.
Versatile and scalable safety architecture for the future
A future-proof SIS must support a variety of form factors and configurations, such as local I/O, remote I/O, and, most important, provides scalability. This flexibility allows businesses to optimize their infrastructure, reduce engineering and installation costs, and tailor systems to their specific operational needs.
One key advantage of these architectures is the option to “mix and match” of communication media types, such as copper and fiber optics. It effectively helps balance performance and cost. For example, fiber optics can be used for long-distance communication across large facilities, while copper can be deployed within buildings to reduce costs without sacrificing performance.
Scalable SIS can start small and expand as needed to grow with the business. Some safety systems could accommodate up to 750,000 I/O points, ensuring long-term relevance and effectiveness for decades to come.
Data-centric approaches and long-term strategies
To be effective, an advanced safety system needs to be versatile and adaptable, capable of handling a wide range of applications and integrating with emerging technologies. For example, artificial intelligence (AI) and machine learning (ML) enhance predictive maintenance, optimize performance, and ensure proactive safety measures. Collecting, analyzing, and acting on vast amounts of data is essential for maintaining high safety standards and operational efficiency.
A long-term strategy that focuses on scalability and avoiding obsolescence is crucial. Systems must grow with technological advancements and evolving industry needs. For example, performing online firmware upgrades without downtime reduces operational disruptions.
Comprehensive safety and cybersecurity integration
In today’s industrial environment, safety and cybersecurity are intrinsically linked. A competitive SIS must integrate comprehensive cybersecurity measures protecting against internal and external threats. Unified certifications for safety and cybersecurity, like ISA/IEC 62443 for industrial automation or IEC 61508 SIL3 for electronic systems, are essential, ensuring that systems deliver the highest levels of integrity and resilience.
EcoStruxure™ Tricon CX embodies these principles, providing a versatile and secure safety system designed for the future:
- Flexible and scalable: Supports various configurations, optimizing infrastructure and reducing costs.
- Unified system: Integrates safety and critical control applications into a single system, simplifying engineering and reducing training and certification efforts.
- Safety and cybersecurity certification: TÜV-certified, ensuring high levels of integrity and resilience.
- Modular digital lifecycle tools: Streamlines design, testing, operation, and maintenance, enhancing efficiency and continuous protection.
- Data utilization strategy: Leverages data for AI and ML, enabling predictive maintenance and proactive safety management while promoting scalability and obsolescence avoidance.
- Future workforce readiness: Simplifies safety for digital natives with a user-friendly design, bridging the knowledge gap as experienced professionals retire.
A safer, more secure digital future
For over 40 years, Triconex has been at the forefront of innovation, setting industry standards and continuously improving safety technologies. Learn more about EcoStruxure™ Tricon CX Version 12, the future-ready safety instrumented system that is flexible, has a robust architecture and advanced data capabilities, by watching this video.
Add a comment