4/9/2015
Lockout/Tagout Beyond the Products: A Roadmap to a Sustainable Lockout Program Edwin Ojeda
Lockout Tagout at a Glance
Lockout • Physically ensuring a machine is inoperable while repairs or adjustments are made with the use of a padlock and a suitable device.
Tagout • Clearly communicating to workers that the equipment is being serviced with labels and tags when lockout is not a viable option.
When it comes to your lockout program, your employees are the priority. They face equipment challenges everyday on the shop floor and deserve protection they can trust.
The Intent Behind Lockout Tagout – Protecting Employees
OSHA’s intent was to protect: • General industry workers performing servicing and/or maintenance on machines or equipment and who are exposed to the unexpected energization, startup or release of hazardous energy. OSHA 29CFR1910.147
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Regulatory Basics – U.S.
OSHA 29CFR OSHA 29CFR ANSI 1910.147 1910.333 Z244.1 2003 Control of Hazardous LOTO & Alternative Electrical Safety Energy Methods
It’s Not Just the United States
Canada • CSA Z460:2013 • Control of Hazardous Energy
Europe • 2006/42/EC – Machine Directive • 2009/104/EC – Work Directive
International • IEC 60204 – Safety of Machinery (Electrical) • ISO 14118 – Prevention of Unexpected Start-Up
The Key to Sustainability
Your Six Steps to LOTO Compliance
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Six Steps in Creating a Sustainable Solutions
STEP 1 STEP 2 STEP 3 Develop and Create and post Identify and mark document your written, equipment- all energy control energy control specific lockout points policy/program procedures
STEP 4 STEP 5 STEP 6 Train your team: Equip your team Sustainability – communicate your with proper lockout Annual audit, review, policy and program tools and warning employee and devices management buy in, customization
Develop and Document Your Energy Control Program
• Your written lockout program establishes and explains the elements of your program
• These need to not only take into account OSHA guidelines, but also: ANSI best practice standards for lockout tagout Employees understanding
• A program is only as effective as its ability to be implemented within the facility
• Programs should be fluid, continuously reviewed and collaborative with employees from all levels of your facility
Create and Post Written Procedures
• Bare minimum requirements include machine-specific lockout procedures with the necessary steps for safely controlling hazardous energy
• Best practice visual procedures are becoming the rule, rather than the exception, within all industries because they clearly indicate isolation points, energy sources and more
• With visual reinforcement, employees are more likely to perform the required steps to keep them safe
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Identify and Mark All Energy Control Points
• Locate and identify all energy control points, including valves, switches, breakers and plugs, with permanently placed and standardized labels or tags
• These labels and tags should be consistent with your equipment-specific procedures
Training Your Team – Communicating Your Program and Vision
• Communicate the contents of the program, but also your vision for your program
• Lockout training includes regulatory requirements and your specific program, procedures, devices and more!
• Training should be provided for: Authorized : Those who perform the lockout on machinery and equipment for maintenance Affected : Those who do not perform lockout requirements, but use the machinery that is receiving maintenance Other : Any employee who does not use the machinery, but who is in the area where a piece of equipment is receiving maintenance
Equip Your Team With the Proper Devices, Tags and More!
• Equip your employees with the proper lockout tools and warning devices
• There are many products on the market, and selecting the best-fit solution for your equipment is the key to employee safety
• Employees should be trained on how to use devices
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The 6 th Step: Sustainability
Enacting Change and Making it Stick
Program Sustainability
• Sustainability in your lockout program goes beyond your annual audit and is embedded in your safety culture Act Plan • You should incorporate sustainability into each previously mentioned step Check Do • Use PLAN DO CHECK ACT methodology to continuously improve your program
The Roadmap to Sustainability: Implementation
• Deploy in other • Develop plan areas of the • Educate those organization involved • Evaluate Act Plan
Check Do
• Audit and • Simplify improve • Standardize • Sustain
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Using Plan Do Check Act
• Deploy in other • Develop plan areas of the • Educate those organization involved • Evaluate Act Plan
Check Do
• Audit and • Simplify improve • Standardize • Sustain
Develop a Plan
• Create a LOTO Program
• Standardize: Act Plan Select based templates for your lockout procedures Select devices Select depots / restocking
Check Do • Revise process to optimize efficiency based on results
Put the Plan into Action
• Have a LOTO program (aligned with other programs)
Act Plan • Have a policy statement (LOTO/Safety)
• Training (affected, authorized, other)
Check Do • Ensure that tools are readily available and identifiable Procedures Devices “Generic Forms”
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Measure & Report – Is it Working?
• Conduct periodic inspections on: Employee knowledge Procedure comprehension Procedure accuracy
Act Plan • Availability: Procedures LOTO equipment Training
Check Do • Employee attitudes toward safety culture
• Make adjustments where appropriate
React to Findings: Keep, Change, Etc.
• Deploy to the rest of the organization: Phased, Contractors, Temp Employees
• Identify areas of progress and opportunity: Act Plan New equipment/hazards Improved/generic forms (interim measures, link forms – confined space, etc.) New technologies (track & integrate Check Do periodic inspections into PM schedules, equipment depots, etc.)
• Identify methods for sustainability: Product ID & stocking Shadow boards Pre-identified hazard zones
Quick Employee Wins to Kick Start Your Program
Services Support • Bring in other, skilled people who may be less familiar with the factory floor arrangements
• Invest, plan, perform hazardous energy & risk assessments to identify the organizations needs proactively
• Continuously identify and recognize those employees who are proactively approaching LOTO safety
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Quick Employee Wins to Kick Start Your Program
Work Efficiency Support • Lockout devices, locks and tags • Shared lock boxes at near equipment • Floor marking • Visual signage and labeling • Printers and consumables • Signs • Tagging (lockout, maintenance, waste, etc.) • Shadow boards
The Lockout Tagout Scavenger Hunt
Machine Specific Procedures • Are your employees trained on them?
Fully Stocked Lockout Tagout Stations • Are they updated?
Permanent Identification Labels • Are they easily identified?
Locks, Tags & Devices • Were they easy to find and the proper devices for the types of equipment?
Tutorial or Training Posters • Do these align with your employee training?
Corporate Safety Messaging • Could your employees easily define these?
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