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OSHA Lockout Safety General Industry


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A lockout presentation that I use in an OSHA 30 hour class.

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OSHA Lockout Safety General Industry

  1. 1. Control of Hazardous Energy 1910.147 Draft 6 27 2016
  2. 2. Lockout/Tagout Need for Lockout - Purpose & Scope of Standard
  3. 3. June 2016 • Plainfield IL • Carlos Rivera, 50, was caught and pulled through a steel baler, authorities said
  4. 4. Jun 2016 • “J was not happy to see their machines with the doors open and they were running.” • The member explained that they were being set up and the adjuster (set up person) was in the process of adjusting the paper correctly.
  5. 5. January 2015 • A 50-year-old temporary worker was permanently disabled after a machine used to package cases of bottled water onto a pallet for shipment started up while he cleared a jam in the machine. • The worker had been on the job for 12 days at the Ice River Springs plant in High Springs, FL. Is there anything that could jam at your place?
  6. 6. May 2014 • A 17-year-old has the ability to move his right arm again, thanks to surgery performed at Massachusetts General Hospital. • Brett Bouchard severed his arm just below the elbow while cleaning a pasta machine at work.
  7. 7. The Need for LOTO • OSHA: failure to control energy accounts for nearly 10 percent of serious incidents • Case Studies from the NIOSH report: Guidelines for Controlling Hazardous Energy During Maintenance and Servicing reports the following: Pasta machine
  8. 8. May 2014 • Milford IL • 3 willful at $70,000 each • The worker was clearing birdseed from a large industrial mixing tank. • The worker’s left hand and arm were crushed after being caught in the moving parts of the mixing machine. • 147(c)(6)(i) • 147(c)(7)(i) • 147(d)(4)(i) The subsequent investigation determined Wagner’s failed to lock out energy sources, which would have protected the worker from contact with rotating components of the machine.
  9. 9. 147(c)(6)(i) • The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements of this standard are being followed.
  10. 10. 147(c)(7)(i)• The employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by employees
  11. 11. 147(d)(4)(i) • Lockout or tagout devices shall be affixed to each energy isolating device by authorized employees. What is missing?
  12. 12. Headlines May 2014 • Company ‘willfully ignored’ safety standards in worker’s death • Daniel Collazo (left) was nearly done with his shift cleaning machines when other workers heard his screams. • Collazo had become caught in the rotating screws that blend the hummus and struggled to free himself as slowly-winding 9-inch blades kept turning, crushing his arms and part of his head. The company paid a $540,000 fine to the Occupational Safety and Health Administration following Collazo’s death in 2011.
  13. 13. Exercise • May 2014 • Paterson, NJ • After entering a die cutting machine to do maintenance, a worker employed for 26 years at was crushed when the die cutter was activated by another employee unaware that the victim was inside. CNC die cutting machine What places could you be in and others are unaware you are in the equipment?
  14. 14. First Day • “A worker’s first day at work shouldn’t be his last day on earth,” was OSHA chief David Michaels’ reaction to the work-related death of Lawrence Daquan “Day” Davis. • The 21-year old was crushed in a palletizer machine on August 16, 2012 at the Bacardi Bottling facility in Jacksonville, FL. Davis was a temp worker hired by Remedy Intelligent Staffing. It was his first day on assignment to the Bacardi plant.
  15. 15. SIGCASE • $207,450 • Worker cleaning equipment in preparation of set-up • Equipment not locked out • Worker not trained • No specific procedures • 5 amputations
  16. 16. Wire Drawing • Severe injuries to worker setting-up equipment • Caught in wire • Machine either auto started or malfunctioned • No lockout • Lack of training
  17. 17. Baler Operation • Worker trying to clear jam • Baler set on auto-start and not locked out! • Worker had no lockout training • Injury - worker could be crushed
  18. 18. Cleaning Hazards • Cleaning a machine is not supposed to be a hazard. • Guards are in place to prevent exposure to hazardous motions. • If guards must be removed to clean, the lockout is required. Cleaning a conveyor is a common source of death and amputations. This conveyor does not have guards for the rotation of the horizontal drive shafts.
  19. 19. Scope of Standard • Covers general industry where servicing & maintenance of machine and equipment can result in unexpected start up or release of stored energy that could cause injury
  20. 20. Not covered • Servicing and maintenance during normal operations (see OSHA Standards subpart O). • Machine Guarding is required then! • Minor tool changes, adjustments during normal operations • Work on cord and plug equipment
  21. 21. Example - Not Meeting Exception • Grand Rapids MI • June 27, 2014 • A proposed $558,000 fine against Grand Rapids Plastics for safety violations tied to a worker's death would be the largest issued by the Michigan Occupational Safety and Health Administration in more than a decade. Russell Scharenbroch
  22. 22. Definitions • Lockout. • Placing a lockout device on an energy-isolating device (in accordance with an established procedure) ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed.
  23. 23. Definitions • Lockout device. • A device that uses a positive means such as a lock, either key or combination type, to hold an energy-isolating device in the safe position and prevent the energizing of a machine or equipment.
  24. 24. Definitions • Authorized employee* - Person who locks or tags machines & equipment to perform servicing • How would this work in multiple shifts?
  25. 25. Lockout - Authorized need to be trained in • recognition of applicable hazardous energy sources in the workplace • the type and magnitude of energy found in the workplace • the means and methods of isolating and/or controlling the energy
  26. 26. Definitions • Affected employee* - Person required to use machines/equipment on which servicing is performed under lockout/ tagout or who must work in such an area
  27. 27. Lockout - Affected • All employees who work in the area where the energy control procedure(s) are utilized need to know about the prohibition against attempting to restart or reenergize machines or equipment that is locked or tagged out.
  28. 28. EXERCISE • What is hazardous energy? • List all Energy sources Pnuematic Compressor
  29. 29. What is hazardous energy? • Energy sources including • electrical • mechanical • hydraulic • pneumatic • chemical • thermal • gravity • radiation • other sources in machines and equipment Some machines like this trim station might have multiple sources of energy.
  30. 30. 192 276 420 443 618 147(d)(4)(i) 147(c)(7)(i) 147(c)(6)(i) 147(c)(1) 147(c)(4)(i) General Environment Controls [1910.141 – .147] 30 LOCKOUT/TAGOUT – DEVELOPED PROCEDURES LOCKOUT/TAGOUT – PROGRAM LOCKOUT/TAGOUT – PERIODIC INSPECTIONS SUBPARTJ LOCKOUT/TAGOUT – GENERAL TRAINING LOCKOUT/TAGOUT – SPECIFIC/ENFORCEMENT OF PROCEDURES Energy control procedures must be in writing including specific procedures for each type of machine
  31. 31. Application of the Energy Control Procedure (in order) 1. Prepare for shutdown 2. Shut down equipment 3. Isolate all energy sources 4. Apply locks & tags 5. Release stored energy 6. Verify equipment isolation 7. Perform the task 8. Release from Lockout
  32. 32. Specific Procedure Example • Shutdown the Mixer at the button. • Verify that all moving parts have stopped. • Lock and tag the knife switch with appropriate lockout devices. (Be sure to use your own personal locks with only one key for each lock, which you hold.) • Verify that the mixer is locked out by pushing on the ON button and seeing that mixer blades do not move. Worker locking out the mixer
  33. 33. Specific Procedures
  34. 34. Specific Procedures • Many are pictures orientation so use for lockout procedures
  35. 35. Verification • EACH energy source must be verified to zero energy state • Capacitors? Heal Sealer fatal in WI. Capacitor discharge.
  36. 36. Verification • Testing circuitry, cycling, visually inspecting position, manually trying; monitoring movement or discharge; observing bleeds, gauges, indicators, etc; or other available means. • Use technique(s) with the best degree of isolation assurance. • Do not rely on pressure gages alone to indicate pressure. They are often inoperable.
  37. 37. Verification Citation $53,900
  38. 38. Verification 2015
  39. 39. Lockout Log • A written procedure should be established with a log to track locations, time, employees and devices.
  40. 40. Periodic Audits • Done at least annually • Conducted by an authorized employee • Must correct any deficiencies • Certified by employer It's also important to test the e-stops, although this is better done at the end of shift because it may be difficult to get the automation running again.
  41. 41. Periodic Audits • Machines where procedures are used • Date of inspection • Employees included in inspection • Person who performed inspection
  42. 42. Lockout Audits • Audit lockout for new people right away vs waiting a year.
  43. 43. Sample Audit Results • Lockout location info not correct • Contractor padlock not identified to who it was protecting • PPE for lockout was not correct for the hazard
  44. 44. Outside Contractors • Must adhere to standard’s requirements • Must inform each other of respective program responsibilities
  45. 45. •Worker died when shocked pulling out barrel fuse with pliers •Electrical circuits must be locked out before doing any work on the circuits if possible. Fuse Pulling
  46. 46. Air Handlers Worker touched an energized horizontal heating coil
  47. 47. Questions