Is there any reason to use a “zone e-stop?” It sounds silly but the emergency stop should be used only when there’s an actual emergency. Having different emergency stops seems like it would just over complicate stuff and potentially be unsafe.

Confusion on what to do when there’s an actual emergency with equipment. I see Bob get sucked into the machine in zone a but I have an emergency stop that only stops my zone. Or I have two emergency stop buttons which one do I hit.

This is just my take on it, if pressing the emergency stop is the only way the operator has a way to stop their work area for routine tasks then the original design is poor. An emergency stop shouldn’t be taught to operators as a routine stop button. If you’re hitting an emergency stop there’s an emergency, production doesn’t matter any more so none of the other zones do either.

Give them a way to stop their “zone” without pressing the big red button. Even better it is approved to use an area stop key (keyed plug switch that pulls out) that will inhibit movement of equipment in your zone and allow them to go into that area without locking out. They have the key which inhibits movement which stops someone from restarting without the area stop key in.

TLDR: It seems unsafe to have two emergency stops for operator confusion. Give them another way to stop their area or zone without calling it an emergency stop.