Kevin Ian Schmidt

Tag: loto

  • Lockout/Tagout Training

    Lockout/Tagout Training

    In the comprehensive landscape of a Hazardous Energy Control Program, the significance of lockout/tagout training emerges as a pivotal and non-negotiable component.

    A key facet of this training is its mandatory nature for individuals engaged in Lockout/Tagout (LOTO) procedures. This training serves as a crucial investment in ensuring that those involved possess a nuanced understanding of the process while upholding the paramount principle of safety. It goes beyond the procedural aspects, providing an in-depth exploration of all facets related to executing a Lockout/Tagout. This includes a thorough explanation of the diverse energy sources that employees may encounter during the lockout process, fostering a holistic comprehension of potential hazards.

    Beyond the training for those directly involved in LOTO, there exists an additional training imperative aimed at employees who will be impacted by Lockout/Tagout measures. These are the “affected employees,” individuals working in areas that are directly influenced by a lockout. The focus of their training extends beyond procedural knowledge; it encompasses a profound understanding of the necessary actions in the event of a shutdown and how to appropriately handle the equipment in their work environment.

    This secondary training layer is designed not only for the direct safety of the affected employees but also bears a critical role in ensuring the well-being of those servicing the equipment. Premature release of a lock can have severe consequences, leading to injuries or even fatalities. Thus, instilling a robust understanding of shutdown procedures and equipment handling among affected employees becomes an integral part of a broader safety strategy.

    Need a more robust loto program? Check out Lockout-out/Tag-out training expanded

    In essence, the training initiatives within the Hazardous Energy Control Program are strategically structured to form a comprehensive safety net. They empower those directly involved in LOTO procedures with the knowledge needed for meticulous execution while extending this understanding to the broader workforce, particularly those working in areas influenced by lockout measures. This dual-layered approach not only meets regulatory requirements but fundamentally prioritizes the safety and well-being of all employees involved in or impacted by Hazardous Energy Control measures.

    An important component for a lockout/tagout program is a quality abandoned lock removal process

    Explore the critical process of safely removing lockout devices in a Lockout/Tagout (LOTO) program. Follow a documented procedure to prevent risks associated with abandoned locks, ensuring employee safety. Learn the Abandoned Lockout Lock Removal Process, approvals needed, and the importance of informing employees. Emphasize safety adherence, OSHA standards, and thorough documentation for a comprehensive lockout/tagout program.

    View the Basic Lock-out/Tag-out Training below:

    LOTO training

    Download the Basic Lock-out/Tag-out Training below:

     

     

    View the Affected Employee Training below:

     

    Affected employee training loto

    Download the Affected Employee Training below:

     

     

    View the Affected Employee Training Video below:

     

  • Lock-out Tag-out Training Expanded

    Lock-out Tag-out Training Expanded

    Keeping everyone safe at work starts with effective lockout/tagout (LOTO) procedures. But simply knowing the steps isn’t enough – employees need hands-on practice and certification to prove they can apply their knowledge in real-world situations.

    Here’s how the process works:

    • Training kicks off: A qualified trainer, either one-on-one or in a classroom, breaks down the LOTO essentials. From identifying energy sources to applying locks and tags, every step is covered.
    • Putting theory into practice: Time to get physical! Under controlled conditions, employees simulate a real LOTO procedure, proving they can apply their knowledge safely and effectively. Pass this test, and you’re officially certified!
    • No one hazard left behind: The best training covers all energy types your workplace throws at you. If you’ve got both electrical and pneumatic dangers lurking around, the certification process should reflect that, using equipment that showcases both risks.
    • Certification with a twist: When it comes to reviewing certifications, there’s a cool twist. Not only does the original trainer observe, but certified employees can also join the party. This creates a self-sustaining “pay it forward” approach to LOTO safety, where everyone takes an active role in keeping their colleagues safe.

    By combining thorough training, hands-on practice, and a dynamic certification process, you can build a workplace where LOTO isn’t just a procedure, it’s a safety culture everyone champions. And that’s something worth celebrating!

    Remember: Safety first, always! Share your LOTO training tips and experiences in the comments below. Let’s keep the conversation going and make sure everyone goes home safe at the end of the day.

    Check Out: How to Put Together a Workplace Safety Training Workshop

    The certification should be performed annually, to ensure employees retain the necessary knowledge to perform their job safely.

    If an employee violates the Hazardous Energy Control Policy, before they can perform lockout/tagout again they must be recertified.

    Retain every certification form for active employees and forms for all terminated employees for 3 years after employment ends. This level of record retention will aid if there is ever an investigation after an injury related to uncontrolled hazardous energy.

    Do you need more components of a lockout/tagout program?

    View the expanded Lockout/Tagout Training below:

    LOTO training expanded

    Download the expanded Lockout/Tagout Training below:

     

    View the Lockout/Tagout Inspection Form below:

    Lockout_Tagout_Inspection

    Download the Lockout/Tagout Inspection Form below:

  • LOTO Lock Removal Documentation

    LOTO Lock Removal Documentation

    As part of a Lockout/Tagout (LOTO) program, there needs to be a process to safely remove lockout devices from equipment without the employee present.

    It is not safe to simply remove a lock from equipment that is locked out without following a documented procedure.

    In the event of an abandoned lock every avenue must be made to contact the employee and ensure they are not in the workplace. Removing a lockout device prematurely can result in an employee being injured or killed!

    Following a documented procedure for this will ensure that no step in the process is missed, which can happen when pressure to re-energize equipment is coming from operations.

    No amount of time pressure is worth an employee’s safety!

    Abandoned Lockout Lock Removal Process

    • In the event that a LOTO Authorized Person is absent, or otherwise unavailable to remove his or her personal LOTO lock(s), the Responsible Individual (RI) may remove the LOTO lock(s) for the Authorized Person, subject to the restrictions in this section.
    • If a Responsible Individual has not been assigned, then either the absent Authorized Person’s supervisor or the Safety Manager (or his/her designee) may perform the task.
    • The following steps must be taken to remove an absent Authorized Person’s personal LOTO lock(s):
      • Obtain a printed copy of the Absent Authorized Person LOTO Lock Removal Form (see bottom of page).
      • Verify that the absent Authorized Person who applied his or her personal lock(s) is not present at the site.
      • Make all reasonable efforts to inform the absent Authorized Person that his/her lockout or tagout device needs to be removed.
      • Make all reasonable efforts to inform the absent Authorized Person’s supervisor that his/her employee’s lockout or tagout device needs to be removed.
      • Permission to remove an absent Authorized Person’s lock must be obtained from each of the following parties:
        • The absent Authorized Person or the absent Authorized Person’s line management and
        • The RI in charge of the specific LOTO, if assigned; or the Safety Manager
    • After obtaining all required approvals, the RI (or Safety Manager designee if necessary) must remove the lock(s). If present, the Absent Person’s supervisor must physically witness the lock removal and must retain possession of the lock(s).

    This policy also needs to include a clause on ensuring the employee is made aware their lock was removed before resuming work. This can be as simple stopping them as they come in the door and inform them this occurred.

    It is also important to recertify the employee for performing lockout/tagout before they are allowed to perform it again, as they violated procedure. This level of adherence to the process is important to safety and the OSHA standard.

    Do you need more components of a lockout/tagout program?

    If you ever have to remove a lockout device, ensure it is fully documented on this form, and retain this form in the employee’s training folder, along with the accompanying recertification form.

    • In the event the key to a lock is lost or misplaced, the lock may be cut by the LOTO Authorized Person after obtaining verbal permission from the Person In Charge of the LOTO.

    View the LOTO Lock Removal Documentation below:

    LOTO Lock Removal form

    Download the LOTO Lock Removal Documentation below:

  • Control of Hazardous Energy Program

    Control of Hazardous Energy Program

    A control of hazardous energy program is very important for workplace safety, and is often overlooked in many workplaces. Many workplaces think they are exempt from the OSHA standards of controlling hazardous energy.

    Control of Hazardous Energy, often just called Lockout/Tagout (LOTO), is the #5 most common cited OSHA violation.

    While often misunderstood, or misapplied, OSHA 1910.147 spells out the applicability of the standard, along with the steps to perform LOTO.

    The foundation of a Hazardous Energy Control Program is a policy that explains all aspects of the program, sets expectations of when LOTO is performed, and by whom.

    Besides a policy there are other important components of a LOTO program, which includes:
    • Training – for those performing Lockout/Tagout
    • Training – for “affected employees”; defined as employees in a work area where LOTO is performed, who may be impacted by the action
    • Annual retraining – Lockout/Tagout is not a set and forget program, it needs to include annual recertification for employees
    • Machine specific procedures – these are documented procedures to perform Lockout/Tagout for each piece of equipment, and needs to be reviewed at minimum annually.

    Do you need more components of a lockout/tagout program?

    Besides the above components, the policy, training,machine specific procedures, and recertifications need to be performed every time a new piece of equipment is added to the workplace.

    To learn more about OSHA 1910.147 Control of Hazardous Energy Standards, OSHA has a published booklet, which helps explain the concepts of the standard, but should not be used to as a substitue for the standard in it’s applicability to workplace safety. View the booklet here.

    If you need to sell the concept of Lockout/Tagout to your superiors, as it does require a substantial investment in time, new safety equipment, and enforcement, CDC/NIOSH has a fact sheet that can be used to explain the standard and it’s importance for workplace safety. View the fact sheet here.

    Failure to have a Lockout/Tagout policy, or even a suitable program, can lead to employee injury or death, and is a direct violation of the OSHA General Duty Clause:

    a) Each employer —

    (1) shall furnish to each of his employees employment and a place of employment which are free from recognized hazards that are causing or are likely to cause death or serious physical harm to his employees;

    (2) shall comply with occupational safety and health standards promulgated under this Act.

    (b) Each employee shall comply with occupational safety and health standards and all rules, regulations, and orders issued pursuant to this Act which are applicable to his own actions and conduct.

    I offer 2 policies for Control of Hazardous Energy:

    1. Is a basic program, which spells out the base minimum of an OSHA compliant program, good for a workplace with minimal need for LOTO, such as one where contractors perform all the work.
    2. Is an advanced policy, in which every component of a quality program is spelled out, including Tagout only, lock removal, and discipline for policy violation.

    View the basic Control of Hazardous Energy Program below:

    Control of Hazardous Energy Program

    Download the basic Control of Hazardous Energy Program below:

    View the advanced Control of Hazardous Energy Program below:

    LOTO policy expanded

    Download the advanced Control of Hazardous Energy Program below:

  • Control of Hazardous Energy Procedures and Policy

    Control of Hazardous Energy Procedures and Policy

    There is no national data available on the number of workers killed each year by contact with uncontrolled hazardous energy. However, during the period between 1982 through 1997, the National Institute for Occupational Health (NIOSH) investigated 1281 fatal accidents as a part of its Fatality Assessment and Control Evaluation Program, (FACE). The FACE program was only active in 20 states during that period so the statistics represent just a portion of American workers. The findings, for this portion of workers, showed that 152 fatalities involved the installation, maintenance, service or repair tasks on or near machines, equipment, processes, or systems.

    OSHA estimates that 29 CFR 1910.147 protects approximately 39 million workers and adhering to its requirements can eliminate nearly 2% of all workplace deaths in areas affected by this rule.

    Basic steps of the control of hazardous energy procedure:

    – Preparation for shutdown
    – Notifying all employees
    – Equipment shutdown
    – Isolation from hazardous energy
    – Render all stored or residual energy safe.
    – Locking & Tagging the machines
    – Performing maintenance or service activity
    – Verification (observation, visual inspection & equipment testing)
    – Removing Locks & Tags
    – Notifying all employees to resume work

    Testing or Repositioning of the Machines During Special Circumstances

    OSHA allows the temporary removal of locks or tags only under special circumstances such as when:

    • The machines need to be tested or repositioned.

    If power is needed to test the machines or reposition the machines, equipment or components, re-energization must follow a specific procedure.

    • When outside contractors are working on-site.

    Both the onsite and off-site employers must communicate about their respective lockout and tagout procedures. Each must be certain that its personnel understand and comply with all restrictions and/or prohibitions of the other employer’s energy control program.

    • When servicing or maintenance is carried out by a group rather than one person.

    The crew or group must follow a procedure that affords all employees a level of protection that is equal to that provided by the lockout/tagout device.

    • When there are shift or personnel changes during servicing or maintenance.

    Either the energy isolating devices must remain under continuous control or the on-coming shift must verify the de-energization and lockout/tagout devices are in place on machinery and equipment.

    Removal of Tags or Lockout Devices for Testing or Positioning of the Machines

    When lockout devices or tags are removed and energy is restored to the machines or equipment for testing or repositioning, authorized employees must take these actions:

    • Check the work area to ensure that all non-essential items are removed and the machines are intact and capable of operation.
    • Check the area around the machinery to be certain all employees have been removed or are in safe positions.
    • Locks and tags are to be removed only by the employees who attached them when possible.
    • Notify all employees before restarting machinery.
    • Energize and reposition machinery.
    • De-energize all systems; isolate the machinery from the energy source.
    • Reapply lockout or tagout devices as specified.

    Removal of Locks and Tags

    1. Inspect the work area to ensure that non-essential items have been removed and that machine or equipment components are intact and operate properly.
    2. Check the area around the machine or equipment to ensure that all employees have been safely positioned or removed from the area.
    3. Make sure that locks or tags are removed only by employees who attached them. When this is not possible, the device may be removed under the direction of the employer, provided he adheres to the specific procedures in the standard.
    4. Notify affected employees after removing locks or tags and before starting equipment or machines.

    These policies must be closely followed – with no deviation. Inconsistency creates confusion and can lead to injury and even death.

    Check out this process for removing abandoned lockout locks

    What is Lock Out – Tag out (LOTO)

    LOTO is a safety procedure followed to declare the industrial machines safe. The machines shall be incapable of starting again without the prior knowledge of all the people involved.

    Lock Out – It means locking the concerned device and keeping it away from any power-inducing source. The machine should not be capable of restarting again without warning.

    This involves locking devices like:

    • Circuit breakers
    • Cable lockouts
    • Valves & springs
    • Disconnect switches
    • Key combinations
    • Pneumatic lockouts

    Tag Out – This refers to a process of labeling the device as powerless. The attached pointer includes: why the tag is there, time of application of the tag, & name of the authorized person.

    All LOTO devices must have some standard functions and should meet the following requirements.

    • Identifying the authorized person
    • High durability level
    • A “Do not open, start” warning
    • Uniform in color, size, print, shape and format
    • Devices should resist early removal, except using specific tools like bolt cutters, wire cutters etc.
    • Non-releasable tags

    Do you need more components of a lockout/tagout program?

    There are three important definitions that are to be kept in mind while following these steps:

    System – This refers to the machinery, process and equipment.

    Authorized Employee – This refers to the person who’s qualified to carry out the lockout process.

    Affected Employee – These employees work in the machines. They are not qualified to carry out the procedure like workers, housekeeping staff, ground staff etc.

    Make sure you have the proper training for your employees:
    Basic Lockout/tagout Training
    Expanded Lockout Tagout Training

    There are several responsible people for the job to take place smoothly.

    The managers are responsible for drafting & updating. Monitoring the job is their primary aim.

    The supervisors are responsible for ensuring that everyone follows protocols.

    The employees are responsible for assisting and reporting issues if/when they occur.

    View the Controlling Hazardous Energy Program below

    Control of Hazardous Energy (Lock-out Tag-out) Policy and Procedures

    Download the Controlling Hazardous Energy Program below