Osha Lockout Tag out

Inspections

Certified

Retraining is required if:

Change in job assignments•Change in machines•Change in energy control procedures

Step 6: Verify Equipment Isolation

Check that other workers are clear of potential hazards•Check that locking devices are secure•Attempt normal startup•Return control to OFF/Neutral

Types of Energy

Chemical•Thermal•Gravity

Inspections

Conducted by authorized employees

Energized

Connected to an energy source, or containing residual or stored energy

What do employees need to know?

Employees need to be trained to ensure that they know, understand, and follow the applicable provisions of the hazardous energy control procedures. The training must cover at least three areas: aspects of the employer's energy control program; elements of the energy control procedure relevant to the employee's duties or assignment; and the various requirements of the OSHA standards related to lockout/tagout.

Why is controlling hazardous energy sources important

Employees servicing or maintaining machines or equipment may be exposed to serious physical harm or death if hazardous energy is not properly controlled

Lockout

Placement of lockout device on an energy isolating device

purpose of lockout/tagout

Prevent the unexpected startup or release of stored energy, Reduce the number of fatalities and injuries, Establish a program and procedures for controlling hazardous energy

Required Training•Other employees in work area

Procedures related to restarting machines

Required Training•Affected employees

Purpose and use of energy control procedures

Required Training•Authorized employees

Recognition of hazardous energy sources

Alternative effective protection

Remote lubricators or other remote devices

Energy Control Procedures

Requirements for testing and verifying effectiveness of lockout devices

Types of minor servicing during production operations

Routine•Repetitive •Integral to the use of the equipment for production

Construction-Installing and setting up-Adjusting, inspecting, modifying-Lubricating, cleaning or unjamming-Tool changes

Servicing and/or maintenance where employees may be exposed to unexpectedstart-up or release of hazardous energy

lockout/tagout

Specific practices and procedures necessary to disable machinery and equipment.

Energy Control Procedures

Steps for placing, removing, and transferring of lockout devices

Energy Control Procedures

Steps for shutting down and securing machines and equipment

How can you protect workers?

The lockout/tagout standard establishes the employer's responsibility to protect employees from hazardous energy sources on machines and equipment during service and maintenance.

true

A set-up person was killed when he entered the machine to remove a jammed part.•The rear guard interlock had been inoperable for about 6 months.

true

A setup person suffered an amputation of a finger when it was caught in a pinch point while making adjustments to a knockout mechanism

true

A supervisor entered an injection molding machine while inspecting for the source of a hydraulic leak when the machine cycled. •The supervisor died from massive head injuries.•Two fixed guards were removed about 12 days prior to the accident.

Step 3: Isolate all Energy Sources

Use energy isolation devices in accordance with established procedures to prevent transmission or release of energy

Control Procedure (Lockout) 1

1.Prepare for shutdown

Control Procedure (Lockout) 2

2.Shut down equipment

Control Procedure (Lockout) 3

3.Isolate all energy sources

Control Procedure (Lockout) 4

4.Apply locks & tags

Control Procedure (Lockout) 5

5.Release stored energy

Control Procedure (Lockout) 6

6.Verify equipment isolation

Control Procedure (Lockout) 7

7.Perform the task

Energy isolating device

A mechanical device that physically prevents the transmission or release of energy

Control Procedure (Lockout) 8

8.Release from Lockout

true

An operator crawled under the machine to pick up parts while it was operating. •His head was crushed when the platen opened.

true

An operator's hand was amputated between the mold halves of an injection molding machine.•Occasionally, the mold would open half way, and parts would stick, so he was reaching in to pull a part off.•Operator was pulling at the part with one hand while holding the gate open with the other hand when the mold closed on his hand.

Energy source

Any source of electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy

Step 4: Apply Locks & Tags

Apply locks and tags to:•Valves•Breakers/electrical disconnects•Mechanical blocks

Certification Requirements

Date of inspection

How can you protect workers?

Develop, document, implement, and enforce energy control procedures.Use only lockout/tagout devices authorized for the particular equipment or machinery Ensure that lockout/tagout devices identify the individual users. Establish a policy that permits only the employee who applied a lockout/tagout device to remove it.Inspect energy control procedures at least annually. Provide effective training as mandated for all employees covered by the standard. Comply with the additional energy control provisions in OSHA standards

What must employers do to protect employees?

Develop, implement, and enforce an energy control program. ■ ■ ■ ■ ■ Use lockout devices for equipment that can be locked out. Tagout devices may be used in lieu of lockout devices only if the tagout program provides employee protection equivalent to that provided through a lockout program. ■ ■ ■ ■ ■ Ensure that new or overhauled equipment is capable of being locked out. ■ ■ ■ ■ ■ Develop, implement, and enforce an effective tagout program if machines or equipment are not capable of being locked out.

Lockout device

Device that uses a physical means to prevent operation of a machine or equipment

Step 5: Release or Block all Stored Energy

Discharge capacitors•Block/disconnect lines•Block or release springs•Block elevated parts•Relieve system pressure •Drain fluids•Vent gases•Allow system to cool (or use PPE)•Apply any additional locks and tags needed

Energy Control Program

Energy control procedures for each type of machine

Step 8: Release from Lockout

Ensure machinery is properly assembled and all tools removed•Ensure that employees are outside of danger zones and are notified that devices are being removed•Remove LOTO devices-Must be removed by authorized employee who applied it

Retraining is required if:

Equipment or processes present new hazards•Inspections reveal deficiencies in employee's knowledge of energy control procedures•Retraining must reestablish employee proficiency

true

Exception to LOTO Minor servicing activities that takes place during normal production when alternative effective protection is used

true

Feeling they can do the task after watching someone else do it

Alternative effective protection

Other effective guarding devices as described in OSHA's Subpart O and the most current ANSI B 151.1 standard

Step 7: Perform the Task

Perform maintenance or service

Inspections

Performed at least annually

Energy Control Program

Periodic inspection to ensure procedures are being followed

Certification Requirements

Identification of equipment or machinery

Inspections

Intended to correct inadequacies identified in program

Alternative effective protection

Interlocked gates and barriers

true

LOTO applies when employee Must place any part of their body into the danger zone

true

LOTO applies when employee Must remove or bypass a guard or safety device

true

LOTO applies when:•Employees are performing servicing and maintenance, and there is a potential for injury from unexpected start-up or release of stored energy

Required Training•Authorized employees

Methods for energy isolation / control

Energy Isolation Procedure (lockout/tagout)

Minimize potential for inadvertent activation and/or release of stored energy•Ensure power to the machine is isolated and locked at control points•Use a method that cannot readily be removed, bypassed, overridden or otherwise defeated.

Step 1: Prepare for Shutdown

Understand equipment hazards•Notify other workers of shutdown

Energy Control Procedures

Must be specific to each type of machine and equipment you are working on

Energy Control Procedures

Must include -Statement of intended use of the procedure

Certification Requirements

Name of person(s) performing inspection

Certification Requirements

Names of employees involved in the inspection

The OSHA standard for The Control of Hazardous Energy (Lockout/Tagout

Title 29 Code of Federal Regulations ( CFR ) Part 1910.147

Energy Control Program

Training and retraining to ensure employees understand the program

Required Training•Authorized employees

Type and magnitude of energy in the workplace

Set-up

Work to prepare a machine to perform its normal production operation

true

causes of accidents-Employees working outside of job description

true

causes of accidents-Inadequate training and/or comprehension

true

causes of accidents-Pressure to meet production goals

Step 2: Shut down equipment

se the normal shutdown procedures•Turn all switches to OFF/Neutral