Lockout Safety Meeting Series

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LockoutSafety Meeting Series
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Lockout Statistics

• In a study conducted by the United Auto Workers,
  20 of the fatalities (83 of 414) that occurred
  among their members between 1973 and 1995 were
  attributed to lockout/tagout
• The energy sources involved in these fatalities
  included kinetic, potential, electrical, and
  thermal energy
• 20 - standard guide for of fatalities that are
  attributed to lockout

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What is Lockout?
Lockout is the use of a lock (or several) to
render machinery or equipment inoperable.
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Hazardous Energy

• Lockout requires identifying and controlling all
  energy sources that could activate moving parts
  on machinery or equipment while workers are
  performing maintenance or other work.

• Electrical
• Chemical
• Pneumatic
• Hydraulic

• Potential
• Kinetic
• Radiation
• Thermal

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5 Basic Steps to a General Lockout

• Identify the machinery or equipment
• Shut off the machinery or equipment
• Identify and de-activate the main energy
• Apply a personal lock and/or tag
• Test the lockout

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Lockout Components

• Lockout Policy (Generic)
• Lockout Procedure (Machine Specific)
• Labels and Identification
• Locks and Tags
• Multiple Person and Point Lockout
• Group Lockout
• Lock Removal Process
• Shift Change/Contractors

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Labels and Identification

• The control panel shut-off must be labeled with
  the name and/or number of the equipment it
  controls
• Hydraulic and pneumatic lines should be coded -
  valves and shut-off points must be marked or
  labeled
• Related systems that are normally locked out
  together should be cross-referenced
• When labels are changed, the old ones must be
  completely removed to avoid confusion

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Locks and Tags

• Every worker required to lockout machinery or
  equipment needs a personal lock and keeps the key
  to that lock in their possession. This lock
  ensures personal lockout protection.
• After locking out, a worker can also affix a tag
  listing the date and time, the names of workers
  involved, the reason for the lockout, etc.
• Electrical system lockouts require a tag, but
  tagout must never substitute for lockout.

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Multiple Person Lockout

• Each person working on the machinery or equipment
  is responsible for locking out the
  energy-isolating device.
• Multiple locks can be applied with scissor
  adapters.

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Multiple Point Lockout

• To effectively lockout equipment with multiple
  energy sources, you will need to lockout several
  energy-isolating devices.
• A specific lockout procedure may need to be
  posted by the machinery or equipment. And rather
  than using several locks, you may prefer to use
  cable for securing several disconnects

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Group/Departmental Lockout

• During all group lockout/tagout operations where
  the release of hazardous energy is possible, each
  authorized employee performing service or
  maintenance shall be protected by his/her
  personal lockout or tagout device and the
  employers group or departmental lockout
  procedure.

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Lock Removal Process

• A personal lock must be removed only by the
  worker who installed the personal lock. If
  necessary, the supervisor or manager in charge
  may have to remove the lock, but only if they
• make every reasonable effort to contact the
  worker who installed the lock .
• make sure that the machinery or equipment can be
  operated safely before removing the lock

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Shift Change/Contractors

• Shift Changes
• Specific procedures must ensure the continuity of
  lockout or tagout protection during shift or
  personnel changes.
• Outside personnel (contractors)
• The onsite employer is responsible for all
  parties at the workplace - including contractors.
  Contractors and contract employees must
  understand and follow work-site safety standards
  such as lockout/tagout.

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Ensure Safe LockoutLives are on the line

• Written Procedures
• Training
• Supervision
• Testing the Lockout
• Regular Inspection
• Follow-up