5. Manufacturing Lockout/Tagout
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Ethical and moral duty, you have a legal responsibility
for safety as a supervisor.
Federal law; supervisors can be held criminally
liable for serious injury or death of an employee if
proved negligent in their duties.
Fines/prison time for serious and/or willful violations.
Legal Responsibilities
6. Manufacturing Lockout/Tagout
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Fine and Jail Sentence
for
Worker Electrocution
Company fined $140,000
Supervisor sentenced to a year in jail
Company had received notification and several warnings that no work was to be accomplished
until a power line crossing the job site was de-energized (locked-out and tagged-out).
Supervisor knowing the hazard, directed an employee to drive a dump truck into the hazard area.
Then provided instructions to the employee to raise the truck bed under the energized power line.
The employee was severely burned and died on the scene.
Information Source: Safety 21 OSHA-Compliant Workplace - October 2003
7. Manufacturing Lockout/Tagout
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Develop company policy for implementing lockout/tagout procedures
for the control of hazard energy during maintenance operations.
Management Responsibilities
Train authorized and affected employees on proper use of procedures.
Establish written machine-specific procedures to include applying
the locks and tags, release, and notification from lockout.
8. Manufacturing Lockout/Tagout
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Supervisors Responsibilities
Ensure initial LOTO training.
Ensure retraining if job assignments change, new machines, control
procedures or modifications occurs.
Monitor refresher training.
Enforcement of machine-specific procedures to include applying
the locks and tags, release, and notification from lockout.
Check for shortcuts, mistakes,
or unsafe work practices.
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Pertains to any
employee whose job
require them to work in an
area where maintenance is
performed
Affected Employee
An individual that
operates the machinery
but does not perform
the lockout procedures
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Affected Employee Responsibilities
Report all unusual situation to your supervisor or foreman.
Stay clear of the area as much as possible.
Watch out for others in the area.
Never attempt to assist if your not properly trained.
Never interfere or tamper with a lock or tag.
13. Manufacturing Lockout/Tagout
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An individual who has been properly trained to use lockout/tagout
procedures on a machinery or equipment that is to be serviced.
Authorized Employee
14. Manufacturing Lockout/Tagout
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Authorized Employee Responsibilities
Verify the isolation.
Properly plan the job.
Notify all affected employees in the area of work.
Shut down the equipment at the operating controls.
Isolate all energy sources to equipment.
Lock and tag all isolating devices.
Dissipate all stored or residual energy sources.
15. Manufacturing Lockout/Tagout
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Could be Both
An authorized employee and an affected employee may be the
same person, when the affected employees’ duties also include
performing maintenance or service on a machine or equipment
that requires lockout tagout procedure.
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Hydraulic Energy Hazards
Energy of liquids under pressure
- Pressure can cause parts to move
- Rapid release can cause injury
- Hydraulic fluid can burn you
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Chemical Energy Hazards
Machinery that use any
chemicals have energy
that can start fires, cause
skin burns and generate
harmful gases or fumes
Lubricants, Hydraulic fluid, Fuels, Coolants, Solvents
29. Manufacturing Lockout/Tagout
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Mechanical Energy Hazard
Parts that store energy sources
A plywood press has stored energy by the hydraulic actuators it uses
Position blocks to
prevent parts from
Falling or moving
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The purpose of lockout/tagout is to prevent energy
sources from accidentally being released while a
machine or equipment is being serviced.
The ultimate goal of lockout/tagout is to protect the
safety and health of employees.
Lockout/Tagout Program
“Over 70% of all accidents come from improperly applied
procedures or non-compliance”
32. Manufacturing Lockout/Tagout
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OSHA requires employers to develop, document, and
implement machine specific procedures for the control
of hazard energy source(s) during maintenance operations.
33. Manufacturing Lockout/Tagout
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LOCKOUT /TAGOUT PROCEDURE
MACHINE NAME AND NUMBER
ENERGY SOURCE(S)
ELECTRICAL CHEMICAL GRAVITY HYDRAULIC
MECHANICAL PNEUMATIC THERMAL OTHER:
LOCKOUT/TAGOUT PROCEDURE
ELECTRIC:
PNEUMATIC:
HYDRAULIC:
RESTORING TO NORMAL OPERATIONS
ADDITIONAL SAFETY FEATURES
34. Manufacturing Lockout/Tagout
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Machinery Lockout/Tagout
7-step process
2. Shut down equipment
3. Isolate all energy sources 4. Install Locks and Tags
5. Verify stored energy shut-
down
6. Verify equipment isolation
7. Release from Lockout
1. Prepare for shutdown
35. Manufacturing Lockout/Tagout
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Step 1
Prepare for shutdown
Must know what energy sources associated with equipment
Electrical
Hydraulic
Pneumatic
Thermal
Mechanical
Chemical
46. Manufacturing Lockout/Tagout
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Step 7
Release from Lockout
Inspect Area and Equipment
Reinstall machine guards
Account for tools and parts
Inform others of equipment start-up
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Conduct annual audits to validate effectiveness of the
lockout/tagout procedures
Review procedures annually or when required, especially
after an accident has occurred.
Additional lockout/tagout requirements:
Maintain an equipment survey that list the equipment
required to have lockout/tagout procedures, type(s) of
energy sources, and magnitude of energy.
*
60. Manufacturing Lockout/Tagout
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Some manufactures install lockout
devices on their equipment but you
must ensure the device completely
de-energizes the machine.
Next Slide
71. Manufacturing Lockout/Tagout
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Some doors and panels are equipped with shut-down switches that
turn off the machinery but do not de-energize the electrical circuits
Next Slide
76. Manufacturing Lockout/Tagout
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1. Employers are responsible for establishing a program consisting of energy control procedures,
employee training and an annual inspection of the procedures? True
2. Employers have the option of using either lockout or tagout to control hazard energy sources
during maintenance operations? False, lockout devices must be used.
3. Electrical circuit breaker boxes must be labeled as to which machinery item they control to enable
emergency shut down of equipment if necessary? True
4. Every form of energy must be isolated and controlled by lockout/tagout and the lockout verified
before beginning work? True
5. Lockout/tagout training is only required if the employer feels that the employee may be accident
prone or after the employee is involved in an accident that is the result of improper lockout/tagout?
False, initial training, new equipment, and if there has been a change to a procedure
6. The employer must develop and document a company lockout/tagout enforcement policy?
True
77. Manufacturing Lockout/Tagout
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7. It’s okay to restart equipment before you replace machine guards if you have someone watch
the open area? False, guards must be in position prior to equipment start-up.
8. An employee may use any available lock, even combination locks when conducting a lockout?
False, only locks identified for lockout purposes. Combination locks are NOT authorized.
9. Lockout/tagout policies describe how a company will conduct the lockout/tagout program,
whereas lockout/tagout procedures detail machine specific requirements for placing a machine
in a “Zero Energy” state. True
10. You are authorized to share your lock or to barrow one if you and the other employee agree?
False, each authorized employee must have their own lock
Lockout/tagout is a seven-step process that must be followed in exact sequence?
Bonus Question
True
88. Manufacturing Lockout/Tagout
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Do you enforce lockout/tagout ??
This worker wished his supervisor
had.
3rd degree burns….failure to deplete
hydraulic pressure -- line ruptured.
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Consultative Services
Consultants are available on a request only basis. They will visit a logging site
and provide advice on safety programs and required safety standards.
Employers scheduled for consultative review and are not subject to inspection
by any other OSHA group.
No penalties are assessed, only a commitment by the employer to heed
advice and make any recommended changes.
Requests are treated on a confidential basis. No information is shared with
other OSHA groups.
90. Manufacturing Lockout/Tagout
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7 Loss Control Field Reps
Field reps carry a variety of safety equipment that is readily available
to our Policyholders.
2 Specialized Trainers
Chainsaw trainer for on-site and felling tree training.
General Industry/Sawmill trainer for on-site OSHA compliance assistance.
Visit their website at www.forestrymutual.com
Additional Logger Services:
Other lines of Insurance
On-Site Job Layout Analysis
On-Site Loss Control Assistance
On-Site Safety Meetings
