LOCKOUT TAGOUT (LOTO)

LOCKOUTTAGOUT (LOTO)

Safety Training

What is LOTO and why does it matter?

Lockout is NOT hitting an E-stop and resetting when the job is completed

Lockout is NOT stopping the machine from the control room while retaining machine power.

Lockout REQUIRES the physical separation of the energy source from the supply point to the affected piece of equipment ("pulling the plug")

Every year, thousands of injuries occur in manufacturing because machines weren’t properly shut down before maintenance or repair. That’s why Lockout/Tagout—LOTO—is critical. It protects you, your team, and ensures a safe workplace.

Failure to Lockout

Employee failed to Lockout the line before performing task

Failure to LockOut Tagout can be Life Threatning

Common Injuries Associated with Machines

• BURNS
• TEARING
• ELECTRIC SHOCK
• HEARING LOSS
• ILL HEALTH FROM OCCUPATIONAL EXPOSURE

• CRUSHING
• CUTTING
• SHEARING
• PUNCTURING
• ABRASIONS

Lockout Tagout Steps

Identify and locate

Shutdown

Notify

equipment or machine if operating, by the normal shutdown procedures.

all affected employees in the area that servicing is about to commence.

Follow the machine specific written Lockout Procedures.

all sources of power to each section of the equipment, both upstream and downstream

Lockout Tagout Steps

Verify equipment is locked out:

• Confirm all personnel are clear of danger.
• Test equipment to ensure it will not start/operate (Bump Test)
• Return operating control to netural or "off" position

Stored or residual energy must be brought to a zero energy state by methods such as grounding, blocking, bleeding down, etc.

After servicing equipment, verify guards are back in place, tools are clear of machines, equipment componets are properly in place.

Deactivate the energy isolating devices. Apply individually assigned locks

Lockout Tagout Steps

10

11

Lockout Tagout

Ensure all employees have been safely postioned or removed from the area. Communicate with all involved that locks are being removed and device will be re-energized.

Ensure

Restart

COMPLETED

equipment according to the normal startup procedure.

equipment operates normally after startup. Communicate to all involved that work is complete.

Individually Assigned Locks

Individually Assigned Locks

All Employees and Contractors must have their own individually assigned locks, which state their name (and company for contractors)

No lock should ever be applied that does not have an employee name or a tag stating why the equipment has been locked out.

LOTO locks must never be used for anything but lockout - they are not to be used for lockers, toolboxes, etc.

GROUP LOCKOUT

For large, complex jobs, group lockout is allowed. Locks applied to individual breakers should be easily identifiable by the lead on the group lock out.

Every employee on a group lockout should go through verification with the group or individually if he/she is joining after group verification was already performed.

GROUP LOCKOUT

Do not apply generic, non-identifying locks to lock boxes.

During a shift change, one employee will leave their locks on until a member of the arriving shift arrives and puts their locks on. Another LOTO form should be filled out.

Group Verification of Lockout

After completing verification, return any non-locking switches to neutral or “off” positions to prevent accidental startup during unlocking procedure

Notify all employees in area that a verification is taking place and radio control room for remote start (if needed).

Prior to beginning work, employees should verify that all sources of energy are locked out by attempting to start up the equipment.

Completion of Lockout

Notify area employees that servicing is complete and return equipment to normal operation.

Ensure all personnel and tools are clear of area before returning equipment to normal operation.

Upon completion of work, remove energy isolation devices.Only the employees who applied his/her individually assigned locks may remove his/her individually assigned locks.

REMOVAL OF LOCKOUT DEVICES

Each lockout device should ONLY be removed by the person who installed it. If the person who installed the lock has left the plant site or is unable to remove their lockout device then the following steps must be followed:

REMOVAL OF LOCKOUT DEVICES

1.

The Employee’s supervisor/coordinator is contacted.

2.

The supervisor/coordinator contacts the designated area owner. Management can authorize the removal of another person’s lockout device only after verifying the employee has left the plant. All reasonable efforts to contact the authorized employee have been made and the employee has been told that they need to return to the plant and remove their device. This is to ensure that the employee has this knowledge before returning to work the next day.

REMOVAL OF LOCKOUT DEVICES

Once the area owner is certain the employee has left the plant site and a qualified secondary individual verification has been performed , the appropriate documentation that the employee has left the plant site should be performed, and removal of the lockout device is then authorized.

3.

Working Near Live Equipment Policy

Working near live equipment may be necessary in all areas of the mill and can be done safely if we follow the Working Near Live Equipment Policy

When hazards cannot be eliminated or controlled then the Working Near Live Equipment Policy must be followed.

KNOWLEDGE CHECK

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