LOTO practices in the manufacturing industry.

1. Basic training for machine operators.
LOCKOUT TAG OUT (LOTO)
Sivasubramaniam Subramanian
ME.OSH Mgt. (UTM)

2. What is LOTO
A process or a practical activity done to control and
isolate all forms of energy supplied to an equipment at
the area of work.
This is done during :
 Planned cleaning activities
 Change Over
 Maintenance
 Servicing
 Removal of guards(fixed)
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3. Why LOTO…….
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 All machines have the potential to cause serious harm.
It is unacceptable for any employee or contractor to put themselves in the
position where it is possible for them to come into direct contact with either
energized equipment or equipment that has the potential to be energized.
 To prevent any unforeseen incidents that can cause harm to you and the
people around you.
 Moving parts of machinery must be guarded; if any work has to be
carried out on the equipment then it must be de-energized from all
direct or stored energy and locked and tagged out

4. 4ENERGY sources.
Employees should know :
 The types of energy resources (energy sources ) used
 Hazards or dangers involved
Types of Energy ;
 Electricity
 Mechanical energy ( eg, conveyor belt , roller , mixer , motor )
 Compressed air
 High pressure steam
 Hydraulic
 Gas
 Thermal
 Gravity
 Water
 Pneumatic
 Springs / capacitors

5. Learning from experience……. 5
Fast moving machines can throw things at
you, cause abrasions and friction burns
Clothes and limbs can get entangled in
machine parts
Moving machine parts can trap you, crush
you, smash into you, or remove body parts
Any intervention to be done, LOTO
MUST BE APPLIED if machine guarding
is not available, moving parts exposed,
guards are easily removed, energy
sources can be activated by others..

6. This can happen ……. 6

7. 7Lockout Devices
• Durable – Lockout and tagout devices must withstand the environment to which they
are exposed for the maximum duration of the expected exposure. Tagout devices must
be constructed and printed so that they do not deteriorate or become illegible,
especially when used in corrosive or wet environments.
• Identifiable – Locks and tags must clearly identify the employee who applies
them. Tags must also warn against hazardous conditions if the machine or
equipment is energized and must include a legend such as:
• Name.
• Reason for tag
• Date
• Permit No.( if the activity has a PTW issued)
• Date Start and Finish (if locked due to project and has a PTW)

8. 8
 Tags are warning device only.
 Tags don’t provide the same level of protection as lockout devices.
 Tags are only for information along with locked devices.
 Tags can only be removed together with locked devices by authorized
person ONLY.
 Tags must be legible (can be read), securely attached and resistant to
degradation.
What is a tag ?

9. 9Examples of Locks and Tags

10. Process flow for LOTO
application
Identify machinery
to LOTO and Notify
adjacent area owner
Shut-down the
machinery /
equipment
Refer LOTO Map to
identify all energy
sources and other
hazards
De-energize all
stored energies
Perform the
required task
LOTO all isolation
points
Test by ‘trying’ to reactivate
the equipment/mach
without exposing the tester
or others to risk
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11. Applying the LOTO 11
1. Stop the machine using CONTROLLED STOP (Start Stop button, Key lock, isolators or
any other stopping mechanism.
2. Obtain a lock and lock the area indicated by LOTO labelling. (1 PERSON, 1 LOCK)
3. If more than 1 person need to lock, Fit a hasp to the isolator (hasps are used so
others can apply their own locks)
4. ALWAYS– Attempt to start the equipment to confirm the LOTO is complete and
successful lock down.
1
2
2 2
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12. Process flow for LOTO removal 12
Only when the intervention work has finished and guards have been replaced,
can LOTO removal process start.
Re-Install all
fixed guards
correctly
Close doors and
hinged covers
Verify all potentially
hazardous areas are
covered as they were
before the
intervention
Each person
who has placed
a lock, may now
remove his/her
lock and the tag
Notify all
affected workers
that “re-start”
will be initiated
Once all locks are removed, main switch
and all other switches (e.g. pneumatic)
may be switched on in order to re-power
the machine
Re-start by per
operator manual
Removal of locks after work has been completed and verified and all tools
used and auxiliary materials have been removed from the work area.
Ensure that the machine is safe to start before removing the isolation.

13. Lock-Out Tag-Out Rules
 Every person required to carry out Lock-Out Tag-Out must be trained to specific
Lock-Out Tag-Out procedures and must carry a personal lock and tag.
 One person one lock – this is for personal use
 One key per lock
 All other keys must be destroyed
 If the key is lost then the lock must be replaced with a new lock
 Each lock must be tagged so that the owner can be identified
 Colleagues that preform Lock-Out Tag-Out must always have access to a lock.
 Following the application of lock-out tag-out, de-energizing of the equipment is to
be proved both of direct and stored energy before beginning any work
 All personnel removed from the danger area and an attempt made to start the
equipment
 Only when work is completed and guards are replaced can LOTO be removed
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14. Lock-Out Tag-Out Rules
 At the point of Lock-Out Tag-Out removal when original owner of a lock cannot
be traced, a procedure for emergency removal shall be in place to be followed
by an authorised competent person
 This procedure can result in a lock being cut from the equipment but only
after all other options have been exhausted.
 Approval for emergency removal must be given by the Plant Manager or
designated person and the Safety Manager upon confirming it is safe to
remove.
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15. 15
Gang Box / Lock Box
Group Isolations.
 Used for complex large and multiple energy isolation.
 A gang box / lock box is used.
 All isolation points / main isolation point will be LOTO by the project lead.
 Project lead will drop the key / keys of isolation points Locked into the gang box.
 Project Team will proceed to lock the Gang Box with their own locks. Keys will be held by them.
 Project lead will verify all related areas LOTO and all those working in the project has locked the gang
box and will proceed lock the gang box with his lock.
 Upon completion of work, the individual team members will remove their locks from the gang box.
 Project Lead will hold onto his key as the last person standing concept and will only remove his lock
from the gang box after all locks have been removed and has confirmed with the team, project has
been completed.
 Project lead will retrieve the keys from the inside the gang box and remove the locks at the isolation
points.

16. LOTO MAP
 A LOTO MAP is required for each machine or machine group.
 It must show the location and function of all isolation points which are relevant for
this machine.
 It could be either shown in a layout or with photos.
 In very complex installations it might be practical to add an overviewing layout to
the machine LOTO MAP’s.
 Also label the isolation point on the map and equipment to show which
machine/energy needs to be shut off.
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17. Shift Change over process.
Scenario : Morning shift (7am – 3pm) does cleaning activity. LOTO has
been carried out. Cleaning activity extends to the next shift (afternoon
3pm – 11pm) due to deep cleaning activity.
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Questions Answers
Can the locks be left in the machine
during pass over?
Nope. During the shift change over,
the incoming operator must place
his/her lock on the isolation points.
Can the keys be given to the next
employee ?
Nope. Locks and keys are not
transferable or shared. One person
one lock one key.
If the next shift employee does not
turn up for work ?
Inform Supervisor. Supervisor to lock
with his lock and indicate on the tag
and log book.

18. Is this right ? 18

19. 19
Sample LOTO training board

20. 20
Lock out / Tag out Devices

21. 21Lock out / Tag out Devices

22. 22
Lock out / Tag out Devices

23. 23
23
Lock out / Tag out Devices

24. 24Labelled Lock Out Points

25. 25
Lock stations.

26. 26
Usage
To lock MCB at
electrical panels
Used to lock
equipment at work
area and tag to
indicate who did the
locking
Used to lock out
valves
Used when more
than 1 person is
required to lock out
at the same point.
QUIZ
Connect the device to the correct usage.

27. TERIMA KASIH / THANK YOU / NANDRI / SEAH SEAH NII
Sivasubramaniam Subramanian
Email : svre.ehs@gmail.com
Mobile : +60164541978