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Lockout Statistics
• In a study conducted by the United Auto Workers, 20% of the fatalities (83 of 414) that occurred among their members between 1973 and 1995 were attributed to lockout/tagout • The energy sources involved in these fatalities included kinetic, potential, electrical, and thermal energy • 20% - standard guide for % of fatalities that are attributed to lockout


What is Lockout?

Lockout is the use of a lock (or several) to render machinery or equipment inoperable.


Hazardous Energy
Lockout requires identifying and controlling all energy sources that could activate moving parts on machinery or equipment while workers are performing maintenance or other work.
• • • • Electrical Chemical Pneumatic Hydraulic • • • • Potential Kinetic Radiation Thermal

5 Basic Steps to a General Lockout
• Identify the machinery or equipment… • Shut off the machinery or equipment… • Identify and de-activate the main energy… • Apply a personal lock and/or tag… • Test the lockout…


Lockout Components
• • • • • • • • Lockout Policy (Generic) Lockout Procedure (Machine Specific) Labels and Identification Locks and Tags Multiple Person and Point Lockout Group Lockout Lock Removal Process Shift Change/Contractors


Labels and Identification
• The control panel shut-off must be labeled with the name and/or number of the equipment it controls • Hydraulic and pneumatic lines should be coded - valves and shut-off points must be marked or labeled • Related systems that are normally locked out together should be cross-referenced • When labels are changed, the old ones must be completely removed to avoid confusion

Locks and Tags
• Every worker required to lockout machinery or equipment needs a personal lock and keeps the key to that lock in their possession. This lock ensures personal lockout protection.

• After locking out, a worker can also affix a tag listing the date and time, the names of workers involved, the reason for the lockout, etc. • Electrical system lockouts require a tag, but tagout must never substitute for lockout.

Multiple Person Lockout
• Each person working on the machinery or equipment is responsible for locking out the energy-isolating device. • Multiple locks can be applied with scissor adapters.


Multiple Point Lockout
• To effectively lockout equipment with multiple energy sources, you will need to lockout several energy-isolating devices. • A specific lockout procedure may need to be posted by the machinery or equipment. And rather than using several locks, you may prefer to use cable for securing several disconnects


Group/Departmental Lockout
• During all group lockout/tagout operations where the release of hazardous energy is possible, each authorized employee performing service or maintenance shall be protected by his/her personal lockout or tagout device and the employer’s group or departmental lockout procedure.


Lock Removal Process
• A personal lock must be removed only by the worker who installed the personal lock. If necessary, the supervisor or manager in charge may have to remove the lock, but only if they:
– make every reasonable effort to contact the worker who installed the lock . – make sure that the machinery or equipment can be operated safely before removing the lock

Shift Change/Contractors
• Shift Changes
– Specific procedures must ensure the continuity of lockout or tagout protection during shift or personnel changes.

• Outside personnel (contractors)
– The onsite employer is responsible for all parties at the workplace - including contractors. Contractors and contract employees must understand and follow worksite safety standards such as lockout/tagout.


Ensure Safe Lockout
Lives are on the line
• Written Procedures

• Training
• Supervision

• Testing the Lockout
• Regular Inspection

• Follow-up


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Tags: health, safety