Brief Guide: Lockout Tagout Procedures (LOTO)

In a manufacturing environment equipment and machinery is a hazard especially during maintenance. Improper operation of equipment can cause sudden start up, electric shock, burns, crush injuries and other accidents. To prevent these incidents Lockout Tagout procedures are put in place to control hazardous energy and ensure energy sources are locked out. It’s important to notify affected employees of equipment shutdowns to keep the work area safe. These procedures require specific employee training, selection of control methods and proper use of lockout and tagout devices. Not only do LOTO protect employees but also extend equipment life and reduce maintenance costs.

But Lockout Tagout procedure violations are one of the most frequent and serious violations OSHA records. The average fine for noncompliance is about $19,000 per case. LOTO compliance prevents 120 fatalities and 50,000 injuries per year so it’s a big deal for worker safety.

What is Lockout Tagout (LOTO)?

Lockout Tagout (LOTO) is a set of procedures that must be followed to protect workers from the release of hazardous energy during equipment maintenance. It includes isolating energy sources such as electrical, mechanical, hydraulic and thermal and using energy isolating devices to lock them out. This prevents accidental start up of equipment and reduces the risk of injury.

An energy isolating device is used to ensure energy isolation points are secure and can’t be accidentally activated during maintenance.

LOTO has two methods:

• Lockout: The use of a lockout device that physically prevents access to energy sources so equipment stays off and safe.
• Tagout (labelling): Placing warning labels on isolation devices to inform employees the equipment is being serviced and not to be turned on until all procedures are complete.

What is Hazardous Energy?

Hazardous Energy is any energy that can harm workers if it’s not controlled or managed during operation, servicing or maintenance of machinery and equipment. Uncontrolled hazardous energy can cause accidents, injuries or fatalities so it’s a big focus in workplace safety protocols like Lockout Tagout (LOTO). Implementing and training workers on hazardous energy control procedures is key so they can safely apply, use and remove energy control devices and prevent accidents during maintenance and service operations.

Types of Hazardous Energy

1. Electrical Energy. Found in live wires, circuits or energized equipment. Risks are electric shock or burns.
2. Mechanical Energy. Found in moving parts, gears, belts or rotating equipment. Can cause injuries such as crushing, pinching or cuts if not stopped or locked out.
3. Hydraulic Energy. Generated by pressurized fluids in hydraulic systems. Risks are sudden release of pressure causing equipment movement or fluid ejection.
4. Pneumatic Energy. Stored in pressurized air or gas systems. Can cause rapid movement of components or high velocity discharge of air/gas.
5. Thermal Energy. From hot or cold surfaces, liquids or steam. Can cause burns, frostbite or thermal shock.
6. Chemical Energy. In reactive substances or stored chemicals. Risks are explosions, toxic exposure or chemical burns.
7. Potential Energy. In objects due to their position such as a raised load or compressed spring. Can cause crushing or impact injuries if released.
8. Stored Energy. In capacitors, flywheels or coiled springs. May cause serious physical injuries.

Benefits of LOTO compliance

There are many benefits to worker safety and operational efficiency from following Lockout Tagout procedures. Lockout tagout devices are key to safety during equipment maintenance and energy control procedures:

• Less Injury: Isolating energy sources minimizes the risk of burns, electrocution, crushing injuries and other accidents.
• Less Downtime: Accidents due to non-compliance with LOTO can cause lengthy production stoppages for repair. Implementing procedures prevents these situations.
• Longer Equipment Life: LOTO maintenance reduces the risk of damage from uncontrolled energy release which means longer equipment life.
• Cost Savings: Less accidents mean lower medical treatment, compensation and legal claims.
• More Productivity: In a safe work environment employees can focus on their work which means more productivity.

These benefits contribute to a company safety culture that affects not only LOTO but other areas of the workplace.

LOTO Procedure Steps

1. Identify Energy Sources: Before starting work you must identify all possible energy sources that could harm you as part of the overall hazardous energy control procedure.
2. Shutdown of Equipment: The device is put into a safe state and the ability to start it is eliminated as part of the loto procedure.
3. Installation of Locks: All control elements of the equipment are locked out so energy can’t be supplied.
4. Labelling: Labels or warning signs are placed to advise the equipment is being serviced.
5. Inspection: A visual check is done to ensure energy is fully isolated. Residual energy must be addressed to make the equipment safe for maintenance.

Employee role in LOTO compliance

Employee training, especially workplace safety training is key to successful LOTO implementation. Every employee must know the procedure, how to use interlocking devices and what to do if non-compliance is found. Regular training and knowledge checks will raise awareness and reduce human error. Also ensure all necessary equipment including guards and safety devices are reassembled before putting the machinery back into service.

LOTO in the future: Digitalization

As technology advances digitisation is key to improving safety and efficiency. Having an energy control programme is critical in this context as it provides a framework for workplace safety that includes lockout/tagout procedures. Specialised applications like ProcessNavigation simplify and optimise LOTO procedures by:

• Giving employees clear real time instructions.
• Allowing supervisors to monitor each step and see deviations.
• Automating tagging and lockout to reduce errors and comply with standards.

Conclusion

Lockout Tagout is part of the safety culture in any manufacturing environment. To be successful it requires compliance with standards, employee engagement, regular oversight and modern technology. Companies that do LOTO are not only safeguarding their workers but also building a solid foundation for long term business success.