2. Frequency Of LOTO Accidents
• 10% of all industrial accidents are LOTO-related
• 250,000 LOTO-related accidents each
year, resulting in approximately:
– 200 fatalities
– 60,000 injuries
3. Cost of LOTO Accidents
• Medical expenses, worker’s compensation
• OSHA fines
• Civil lawsuits
• Low employee morale
• Equipment damage, lost productivity
• Higher insurance premiums
4. OSHA LOTO Regulations
OSHA Standard 29 CFR 1910.147
“Control of Hazardous Energy (Lockout/Tagout)”
Does not cover:
– Work on electrical systems (1910.333)
– Electrical Power Generation (1910.269)
– Construction (1926.416-417)
– Oil / gas drilling and servicing
– Agriculture
– Maritime
5. LOTO Program Components
4 key components of a LOTO program:
• Documented policies and procedures
• Energy source ID
• Employee training
• Proper tools and devices
6. Energy Control Policy
• Purpose and scope of LOTO program
• Equipment covered under the program
• Who is authorized to perform LOTO
• Enforcement policy
• Group lockout procedures and shift transfers
• Procedures for lock removal
• Coordination with contractors
7. Lockout Procedures
• The KEY to a compliant, efficient lockout process
– Inadequately documented procedures is one of the
most frequently cited failures in LOTO violations
• Additional benefits of good procedures:
– Simplifies training
– Helps prevent errors, enhancing safety
– Speeds lockout, shortens downtime
8. Procedure Requirements
• Separate procedure required for each piece of
equipment to be locked out.
• Multiple machines can be grouped under one procedure
only if they have:
– the same type and magnitude of hazardous energy
– the same or similar means of controlling that energy
• Documentation not needed for single-source equip.
• Procedures must be audited at least once per year.
9. Procedure Contents
Application of lockout
• Notify & brief
• Shutdown
• De-energize
• Apply LOTO devices
• Release stored energy
• Verify zero energy state
• (Put warnings in place)
Release of lockout
• Inspect machine / area
• Confirm people are clear
• Verify controls in neutral
• Remove LOTO devices
• Re-energize
• Notify
• Startup
10. Sample Lockout Procedure
• Equipment identified at top
• Provides clear step-by-step
instructions
• Uses color, pictograms to
highlight energy sources
• Use of photos ensures that
workers can quickly find the
correct control points, avoiding
lost time and mistakes
12. Energy Source Identification
Identify hazardous energy sources to
prevent mistakes, speed lockout activity.
Alternative Solutions:
• Stock labels and tags
• Do-it-yourself printing systems
• Custom printed or engraved tags
13. LOTO Training
• Separate training must be provided for the
following types of workers:
– Authorized employees
– Affected / other employees
• Employers must keep a record of all training
• Retraining for authorized & affected employees
• Additional training required for tagout
14. Training & Awareness Aids
• Training Videos
• Training Booklets
• Posters
• Signs & Labels
• Hard hat stickers
15. Lockout & Tagout Devices
Lockout and tagout devices must:
• Be provided by employer
• Be standardized and distinguishable from locks and
tags used for other purposes.
• Be used for LOTO purposes only
• Be capable of withstanding the usage environment
• Identify the person who applied the lock/tag
16. Exclusive Control
Each employee must have exclusive control of the
locks they use. No worker should be able to open
another another worker’s lock!
18. Tags
• Tags can be used alone (as tagout
devices) or in combination with
locks (for ID purposes).
• Requirements For Tagout:
– Must be strong enough to prevent
accidental or inadvertent removal.
– Use non-reusable nylon cable tie or
equiv. that withstands 50-lb pull test
– Must include warnings and
instructions (eg, Do Not Operate)
understandable to all employees
