machine tool authorization system

[vavet]

I run an engineering test lab in a factory. We have a lathe and mill. Although no one should be using it without proper training, I'm fairly certain we have people who do, including people from other departments who might sneak in on a weekend to use it.
I'd like to put an end to it.

In my dream world, this would take the form a a biometric ID that would unlock the machine for a certain time period to allow use. That's probably not going to happen.
What about an electronic keypad in which every user had their own access code and a memory so I could see who accessed it and when.
The most basic system would be asking our plant electrician to install a disconnect between the breaker panel and the control box since these machines are hard-wired. It could be padlocked and every authorized user would have a key to the padlock. Then I'm relying on people to relock the machine.

What other options do I have? What is the viability of the keypad access?

 

[cvairwerks]

Cypherlocks on the lab door....Individual codes, computer tracked, auto lock when the door closes, alarm when door propped open for more than a set time.

 

[XJSuperman]

I know a company that uses keycards for machine access. A friend works in a similar lab to your description and says they have to have their ID cards to run the machine. Its a liability and safety hazard on the company if there are unauthorized users.

 

[4xdog]

There are probably several levels of "control" one can imagine here.

The first is policy and training.

In my years with DuPont, if someone were to use equipment specifically marked as for trained and authorized users only -- when they were neither -- it could easily mean their immediate dismissal. Following safety polices, regulations, and training were a condition of employment.

In our back lab we had a large hand-operated guillotine-style paper cutter. That one was authorized/trained users only, and we had procedures for it and a list of approved operators. People who worked in that area weren't simply allowed to give permission, either, as in "Well Joe said I could use it." We had a simple wheel type cutter in the front lab that we let other labs come in to use.

The second is engineering.

The power supply doesn't have lock-out/tag-out provisions now? I'd probably have your maintenance guys install something like that as an engineering control just as good practice.

 

[vavet]

Cypherlocks on the lab door....Individual codes, computer tracked, auto lock when the door closes, alarm when door propped open for more than a set time.

There are legitimate reasons for other people to be in the test lab itself, usually as a way for our tech support personnel to look at things so they can help customers who call in and need help troubleshooting. The lab is fenced and has magnetic locks on the gates. The people who need access have it, but it's all or nothing. We don't have a way to lock down the machine tools.

 

[LXCam]

Hirsch makes a fully integratable card access system you could make work for this application. All you really need is the dry contact output wire in series with the machine control circuit and you can set the authorization priorities accordingly as well as track everything.

 

[nh_yota]

Does your company issue RFID badges to all employees for building access? If they do, then half of the problem is already solved.

 

[matt_i]

Lockout the machines on Friday and unlock them Monday (?)

Seems like during the basic 40 hour week, unless the shop is remote and/or lightly traveled, people who normally work in that dept have some idea of who is using it.

Simple 3 pole non-fused disconnect wired between circuit panel and machine, actually a good continuous improvement for LOTO reasons.

See also: lock the circuit panel (some have light duty locks on the access door) with breakers off.

 

[Citation]

How much can you do yourself? I can envision a system where a swipe card reader (do you have employee IDs?) sends a 12V signal to a relay to power up the machine. The relay could be placed in line to the main motor so things like the DRO's could be powered but the motor would be off line. You would have to figure out how to shut things down. Would it be automatic after X min/hours, manual log out etc? I'm sure the log out could be done with some automation timers. I could see something with a swipe card reader that triggers a "go", a log out button, timer that warns a long out will occur say in 20 min (press "stay logged in" to reset timer) etc. I'm not describing an off the shelf solution but one that would be familiar to people who have done basic automation with things like timers, relays and resets.

 

[Dave455]

Firstly, think about what the level of risk actually is?

In my experience, I’ve seen far more injuries arise from hand held power tools than from machine tools.

If I thought there was a real problem / risk / liability then I’d simply lock out the power, and give the key to anyone who was authorised. End of problem!

I think you are thinking that way yourself! If folks can’t be trusted to re lock the machine (if that's what you want) then they probably shouldn’t be using it.

 

[Mr. T]

Not to be a downer but is it more of a culture problem? Engineers like to make controls. But if no one is enforcing the rules as they stand, engineering controls mean very little.

Give me about 10 minutes and I’ll bypass just about any engineering control you can think of for these machines. If you’re really good it might take me 25.

A physical key will be not so well hidden. A keypad is going to have the access code written on it. Badges will get shared. Biometrics are gonna be expensive and not always work (dirty hands annoy fingerprint scanners).

If you want to be punitive, everyone signs that they won’t use X machine until properly trained. And when someone does, nail them and make sure everyone knows why.

If you want to be proactive, let it be known that anyone who might need to use these machines will be trained appropriately. Write it up as a CI project that increases or reduces something or other.


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[mikegt4]

Good luck with your project. I worked in a R&D facility with a machine shop and we always had a problem with unauthorized users. To compound the problem the management had contractors on site to do construction, maintenance and change over operations and they had full time access to the shop. Every Monday we would find the belt sander with ripped belts, grease in the media blaster and broken mill bits in the trash. To top it all off the project engineers would help themselves to the equipment if they felt that their project wasn't being done fast enough. Despite many warnings, policy changes, authorized user lists, locks and much finger wagging the problem persisted at least until I retired and probably remains today.

 

[darkzero]

Cypherlocks on the lab door....Individual codes, computer tracked, auto lock when the door closes, alarm when door propped open for more than a set time.

Iris scanner!

 

[SeisMec]

A security camera that records whenever the machine is turned on?

 

[PugetDude]

Discipline; strongly enforced. If employees know there are consequences for inappropriate use of machinery they are not qualified to operate they will quit using it.

"Did you hear Joe got written up/suspended/fired Friday for using the mill/lathe in the lab? Wow, I guess they are serious"

 

[txvwnut]

At my day job I have manual disconnects on all the machines which I keep turned off and locked and I have the key. This has brought machine destruction to a halt.

 

[Al Borland]

Sharks! With Frickin' laser beams attached to their heads!

 

[Made in USA]

motion activated security camera. Ring sells one that will send you a text if someone enters during off hours, lets you review recordings of times when motion is detected, and allows you to live view any time. About $60, connects to your wifi network.

 

[MushCreek]

This reminds me of an event that happened about 45 years ago, early in my career. The company president came in on the weekend, and was using the tool room band saw to make new rockers for a rocking chair. He left everything piled on the machine, and of course, no one knew who's mess it was. The tool room foreman came in Monday morning, and pitched a fit. He cut the rockers into pieces, and waited for the perpetrator to show up. I would have loved to seen the look on his face when he found out who it was! To his credit, the president apologized and cleaned up his mess.

As for a solution, on Friday night, put dabs of Hi-Spot blue under the handles. Look for the Smurf come Monday morning. If I was serious about it, I'd go with a wifi camera.

 

[matt_i]

After some more thought...

The machine tools are useless spindles without the edge tools.

Lock up the edge tools and their holders, collets, tool blocks and the machine isn't very useful.

Higher stakes is to also lock up the mill's vise and the lathe's toolpost.

 

[Tallpilot]

All of these solutions and the most obvious is missed. Stop taking the weekend off.

 

[American Locomotive]

If the machines are hardwired, they should probably have a disconnect at the machine anyways. Just put a lock on the disconnect.

 

[ttpete]

The mill's easy enough, just lock up all of the collets, chucks, and crank handles for the knee and vise in the cabinet with the other mill tools. The same goes for the lathe. and you could also run a chain through the headstock spindle and padlock it.

What we had trouble with was the big grinder. Some idiot would use it for aluminum and load the wheels up. Those and all of the other machines got power from a 240V bus duct in the overhead, and the disconnects were up in the bus plugs. I made a stick to operate them and hid it after I shut everything off at quitting time.

 

[danielbuck]

Does your company issue RFID badges to all employees for building access? If they do, then half of the problem is already solved.

Yeah! And once you hook up the beeper to the machines, just like door access beepers, you'll know who the last person was who used it. And also just like door access batches, you can (fairly real time) gain or remove access to anyone.

 

[PugetDude]

So many cumbersome and expensive proposals to avoid enforcing simple workplace rules....

 

[vavet]

Op here...our plant electrician installed a disconnect on both machines. I’ll put a padlock on each of them and have keys go only to authorized users.
The next step is to figure out who those authorized users are. We will need some sort of competency exam to determine who should be able to use this equipment.

Thank you to everyone for the suggestions.

 

[Mr. T]

I’ll put a padlock on each of them and have keys go only to authorized users.

Best of luck! Let us know how it works out.



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[gearhead1]

Yep, this is what we put on the end of the cord.

https://www.jjkeller.com/shop/Produ...MIh47T9d-C6gIVgwiICR0WsgbfEAQYAyABEgKhf_D_BwE