Lockout Tagout Training by Forestry Mutual
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This document provides information on lockout/tagout procedures for manufacturing facilities. It discusses management and supervisory responsibilities for developing and enforcing lockout/tagout policies and procedures. It outlines the roles and responsibilities of authorized employees and affected employees. It describes the seven step lockout/tagout process and provides examples of locking out different energy sources like electricity, hydraulics, pneumatics etc. It discusses proper lockout practices and examples of improper practices. It includes signage related to lockout/tagout and examples of accidents that could occur from not following procedures. Finally it discusses OSHA consultative services available to assist with safety programs.
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Lockout Tagout Training by Forestry Mutual
- 2. Manufacturing Lockout/Tagout Page 2 Management / Supervisory responsibilities Legal Responsibilities LOTO Personnel LOTO Procedures LOTO Energy Source(s) TOPICS OF DISCUSSION
- 3. Manufacturing Lockout/Tagout Page 3 Lock and tag is a two part process. The lock disables and the tag is a warning. Lockout/ Tagout Process
- 5. Manufacturing Lockout/Tagout Page 5 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 Page 6 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 Page 7 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 Page 8 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.
- 10. Manufacturing Lockout/Tagout Page 10 An Authorized Employee Or Both ! Your Role You are either an Affected Employee
- 11. Manufacturing Lockout/Tagout Page 11 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
- 12. Manufacturing Lockout/Tagout Page 12 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 Page 13 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 Page 14 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 Page 15 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.
- 16. Manufacturing Lockout/Tagout Page 16 LOTO ENERGY SOURCES
- 17. Manufacturing Lockout/Tagout Page 17 Types of Energy Electrical Thermal Mechanical Chemical Hydraulic Pneumatic Could be more depending on machinery type ! Air
- 18. Manufacturing Lockout/Tagout Page 18 Electrical Energy Hazards Can cause shock and/or fire
- 19. Manufacturing Lockout/Tagout Page 19 Hydraulic Energy Hazards Energy of liquids under pressure - Pressure can cause parts to move - Rapid release can cause injury - Hydraulic fluid can burn you
- 20. Manufacturing Lockout/Tagout Page 20 Hydraulic values must also be locked out Next Slide
- 21. Manufacturing Lockout/Tagout Page 21 Holes drilled in handles to lockout with a chain.
- 22. Manufacturing Lockout/Tagout Page 22 Boiler Cold fluids can cause severe injury Thermal Energy Hazards Energy of Heat /Cold Hot equipment & fluids will burn you
- 23. Manufacturing Lockout/Tagout Page 23 Pneumatic Energy Hazards Energy of compressed gases Uncontrolled release can cause injury Properly vent all systems before starting maintenance
- 24. Manufacturing Lockout/Tagout Page 24 Six-point hasp used to lockout air valve
- 25. Manufacturing Lockout/Tagout Page 25 Pneumatic energy can be very dangerous
- 26. Manufacturing Lockout/Tagout Page 26 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
- 27. Manufacturing Lockout/Tagout Page 27 Mechanical Energy Hazards Two Types 1. Parts that are still in motion 2. Parts that store energy sources
- 28. Manufacturing Lockout/Tagout Page 28 Mechanical Energy Hazard A chipper or hog can remain in motion long after power is locked out Parts that are still in motion
- 29. Manufacturing Lockout/Tagout Page 29 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
- 31. Manufacturing Lockout/Tagout Page 31 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 Page 32 OSHA 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 Page 33 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 Page 34 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 Page 35 Step 1 Prepare for shutdown Must know what energy sources associated with equipment Electrical Hydraulic Pneumatic Thermal Mechanical Chemical
- 36. Manufacturing Lockout/Tagout Page 36 Step 2 Shut down equipment Use normal shutdown procedure
- 37. Manufacturing Lockout/Tagout Page 37 Step 3 Isolate all energy sources Turn off power at machinery
- 38. Manufacturing Lockout/Tagout Page 38 Turn off power at machinery at electrical circuit breaker boxes
- 39. Manufacturing Lockout/Tagout Page 39 Turn off Air and Hydraulic pressure
- 40. Manufacturing Lockout/Tagout Page 40 Step 4 Install Locks and Tags
- 41. Manufacturing Lockout/Tagout Page 41 Remember to put the key in your pocket – never leave it in the lock
- 42. Manufacturing Lockout/Tagout Page 42 Step 5 Verify stored energy is shut-down Ensure saw blades have come to a complete stop before removing guards
- 43. Manufacturing Lockout/Tagout Page 43 Ensure cutter heads are not in motion
- 44. Manufacturing Lockout/Tagout Page 44 Step 6 Verify equipment isolation Try to restart machinery following normal procedures
- 45. Manufacturing Lockout/Tagout Page 45 Machinery is now safe for maintenance operations
- 46. Manufacturing Lockout/Tagout Page 46 Step 7 Release from Lockout Inspect Area and Equipment Reinstall machine guards Account for tools and parts Inform others of equipment start-up
- 47. Manufacturing Lockout/Tagout Page 47 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. *
- 49. Manufacturing Lockout/Tagout Page 49 Lockout Program Awareness Posters
- 50. Manufacturing Lockout/Tagout Page 50 Many employers now post their lockout procedures
- 51. Manufacturing Lockout/Tagout Page 51 Unique Idea Color coded breaker boxes with drawings to the machines they controls
- 52. Manufacturing Lockout/Tagout Page 52 Unique Idea Color coded breaker box with drawings
- 53. Manufacturing Lockout/Tagout Page 53 Wooden box used to control electrical hazard for machine plug
- 54. Manufacturing Lockout/Tagout Page 54 Single-point breaker clip used on multiple circuit breaker box Next Slide
- 55. Manufacturing Lockout/Tagout Page 55 Single-point breaker clip Next Slide
- 57. Manufacturing Lockout/Tagout Page 57 Cables used to control electrical hazard for multiple electrical circuit breaker boxes
- 58. Manufacturing Lockout/Tagout Page 58 Hinged brackets used to control electrical hazard for multiple electrical circuit breaker boxes
- 59. Manufacturing Lockout/Tagout Page 59 Holes drilled in handles to lockout with a chain.
- 60. Manufacturing Lockout/Tagout Page 60 Some manufactures install lockout devices on their equipment but you must ensure the device completely de-energizes the machine. Next Slide
- 61. Manufacturing Lockout/Tagout Page 61 Manufactures lockout devices Next Slide
- 62. Manufacturing Lockout/Tagout Page 62 Must ensure that manufacture locking devices are in compliance with OSHA requirements
- 64. Manufacturing Lockout/Tagout Page 64 Improper Lockout Locking out control panels does not eliminate power source to the machinery. Next Slide
- 65. Manufacturing Lockout/Tagout Page 65 Improper Lockout Control panels are energized with 110 voltage. Next Slide
- 66. Manufacturing Lockout/Tagout Page 66 Improper Lockout Most machinery in sawmills operates on 440 voltage. Next Slide
- 67. Manufacturing Lockout/Tagout Page 67 Improper Lockout Locking out control panels does not de-energize the machine
- 68. Manufacturing Lockout/Tagout Page 68 Emergency shutdown switches do not turn off main power source to machine. In fact they have been known to malfunction.
- 69. Manufacturing Lockout/Tagout Page 69 Emergency shutdown switch with protective device but no substitute for locking out electrical circuit breaker box.
- 70. Manufacturing Lockout/Tagout Page 70 A hasp positioned over start button but no substitute for locking out electrical circuit breaker box.
- 71. Manufacturing Lockout/Tagout Page 71 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
- 72. Manufacturing Lockout/Tagout Page 72 Door and panel shut-down switches are not a substitute for locking out electrical circuit breakers prior to maintenance
- 73. Manufacturing Lockout/Tagout Page 73 Employee observed clearing wood debris without locking out machinery or wearing eye protection.
- 74. Manufacturing Lockout/Tagout Page 74 Employee reaching into machine to clear wood debris without locking out machine or wearing eye protection Not observing “Danger Signs”
- 76. Manufacturing Lockout/Tagout Page 76 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 Page 77 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
- 79. Manufacturing Lockout/Tagout Page 79 Warning signs you may see
- 80. Manufacturing Lockout/Tagout Page 80 Warning signs you may see
- 81. Manufacturing Lockout/Tagout Page 81 Warning signs you may see
- 82. Manufacturing Lockout/Tagout Page 82 Warning signs you may see
- 83. Manufacturing Lockout/Tagout Page 83 Accidents you may see:
- 88. Manufacturing Lockout/Tagout Page 88 Do you enforce lockout/tagout ?? This worker wished his supervisor had. 3rd degree burns….failure to deplete hydraulic pressure -- line ruptured.
- 89. Manufacturing Lockout/Tagout Page 89 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 Page 90 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
Editor's Notes
- <number> The Parts of a lockout/Tagout are: <ENTER> The Lock <ENTER> And the tags
- <number> You have an important role. <ENTER> <ENTER> <ENTER>
- <number> <ENTER> Any one who has not been trained and authorized to do lockout/tagout/verify. MAJOR POINT Never puts a lock or tag on a piece of equipment.
- <number> <ENTER> <ENTER> <ENTER> <ENTER> Those who may be in the area and need to give the job a wide berth.
- <number> <ENTER> Any one who has not been trained and authorized to do lockout/tagout/verify. MAJOR POINT Never puts a lock or tag on a piece of equipment.
- <number> <ENTER> <ENTER> <ENTER> <ENTER> <ENTER> <ENTER> <ENTER> Those who perform the work from the planning to the re-start. MAJOR POINT Authorized employees should tell affected employees job is complete before they remove their locks and tags and turn the equipment back on.
- <number> <ENTER> Any one who has not been trained and authorized to do lockout/tagout/verify. MAJOR POINT Never puts a lock or tag on a piece of equipment.
- <number>
- <number>