LOCKOUT

1. The employee is required to remove or bypass a guard or other safety device during service and maintenance.

2. An associated danger zone exists during a machine operating cycle.

3. The employee is required to place any body part into an area of the machinery or equipment where work is actually being performed upon the material being processed.

Minor tool changes, adjustments, and other minor service activities, which take place during normal production, are not included in the Lockout/Tagout Standard provided they are:

1. Routine, repetitive, and integral to the use of the equipment, and;

2. That they are performed using alternative measures which provide effective protection for the employee.

Most people immediately think of electricity as a potentially hazardous energy source. There are other sources of energy, though, that can be just as hazardous. These energy sources include thermal, chemical, pneumatic, hydraulic, mechanical, and gravity. It is important to remember that all sources of energy that have the potential to unexpectedly start-up, energize, or release must be identified and locked, blocked, or released before servicing or maintenance is performed.

The basic equipment needed for a lockout/tagout procedure are locks and/or tags. Locks are to be utilized whenever possible. Both locks and tags must clearly indicate the identity of the employee who applied the device. This provides positive identification as to who is servicing the machinery and equipment. The identification will also indicate who may not have finished working in a multiple lockout/tagout situation. The locks and tags must be durable enough to withstand the environment in which they will be used. Information on the locks and tags must remain legible. Locks must be substantial enough to prevent removal without the use of excessive force. Tags must be substantial enough to prevent accidental or inadvertent removal. Both locks and tags are to be standardized by either color, shape, or size. Tags must have a standard print and format. If an energy isolating device is not capable of being locked out, a tag is to be used. An energy isolating device is simply a mechanical device that physically prevents the transmission or release of energy. All machinery and equipment must be designed to accept a lockout device when major replacements, repairs, renovations, modifications of machinery or equipment are performed, or whenever new machinery is installed.

Employee Classifications

Two types of personnel are directly affected by the Lockout/ Tagout Standard:

Affected Employees - OSHA defines an Affected Employee as an employee whose job requires him/her to operate or use machinery or equipment on which servicing or maintenance is being performed under a lockout/tagout procedure or whose job requires him/her to work in an area in which servicing or maintenance is being performed under a lockout/tagout procedure.

Authorized Employees - OSHA defines an Authorized Employee as an employee who implements a lockout/tagout procedure on machinery or equipment in order that servicing or maintenance may be performed. Often, an authorized employee and an affected employee may be the same person.

Steps in a Typical Lockout/Tagout Procedure

An actual lockout/tagout procedure is simple and straightforward. There are two phases to the procedure.

Phase I - Locks, Blocks or Releases Energy

1. The authorized employee notifies all affected employees that a lockout/tagout procedure is ready to begin.

2. The machinery or equipment is de-energized.

3. The authorized employee releases or restrains all stored energy.

4. All locks and tags are checked for defects. If any are found, the lock or tag is discarded and replaced.

5. The authorized employee places a personalized lock or tag on the energy isolating device.

6. The authorized employee tries starting the machinery or equipment to ensure that it has been isolated from its energy source. The machine is then de-energized again after this test.

7. The machinery or equipment is now ready for service or maintenance.

Phase II - Return the Machinery or Equipment to Production/Service

1. The authorized employee checks the machinery or equipment to be certain no tools have been left behind.

2. All safety guards have been checked to be certain that they have been replaced properly.

3. All affected employees are notified that the machinery or equipment is about to go back into production.

4. The authorized employee performs a secondary check of the area to ensure that no one is exposed to danger.

5. The authorized employee removes the locks and/or tags from the energy isolating device and restores energy to the machinery or equipment.

NOTE: This basic example of the lockout/tagout procedure is used when only one person is performing service or maintenance on machinery or equipment and when no testing or positioning of the equipment is required. Refer to the equipment specific lockout/tagout procedure on this web page for all other lockout/tagouts. Notify the SEFSC ES&H Compliance Officer and Supervision if additional equipment specific lockout/tagout procedures are needed.

Multiple Lockout

In a multiple lockout/tagout procedure, each person working on the machinery or equipment must place a lock or tag on the energy isolating device. If the energy isolating device will not accept multiple locks or tags, a hasp (a multiple lockout device) may be used. The locks or tags must be placed in such a way that energy cannot be restored to the machinery or equipment until every lock or tag is removed. As each employee involved no longer needs to maintain his/her lockout/tagout protection, that employee removes his/her lock or tag. The employee attaching the lock or tag is the only person authorized to remove the lock or tag.

Testing And Positioning

Before a machine can be placed in service the positioning of parts is sometimes required. The following procedure should be followed when testing or positioning machinery or equipment during service and maintenance:

1. The authorized employee makes certain that the work area is clear of tools and materials.

2. The authorized employee notifies all affected employees that the machinery or equipment will be positioned or tested.

3. All employees leave the area.

4. Locks or tags are removed.

5. The machine is started and tested or positioned.

6. When testing or positioning is complete, the machinery or equipment is de-energized following the proper lockout/tagout procedure for servicing or the machine is returned to production via the appropriate procedure.

Inspections And Training

Each energy control procedure must be inspected at least annually for the purpose of ensuring that the requirements of the Lockout/Tagout Standard are being met. Each inspection will be conducted by an authorized employee other than the employee who normally uses the machinery or equipment or performs the lockout/tagout procedure. After each inspection, the employer must certify that the inspection has been completed.

All employees working in an area requiring lockout/tagout procedures must be trained. Training must include:

1. The recognition of lockout/tagout devices and the importance of not disturbing or removing them unless authorized.

2. The safe application, use, and removal of energy controls.

3. The limitations of tags in a lockout/tagout procedure.

Training must occur whenever there is a change in job assignment, a change in machinery or equipment, an energy control procedure change, or a change in a process that presents a new hazard. Retraining is to be conducted whenever the employer believes that employees' knowledge of energy control procedures is inadequate and as part of the annual inspection.

Outside Personnel

When outside personnel, such as contractors, are on site and engaged in activities that require compliance with the Lockout/Tagout Standard, the on-site employer and the outside employer must inform one another of their lockout/tagout procedures. It is the responsibility of the on-site employer to ensure that his/her employees understand and comply with the methods of the other's lockout/tagout procedures.

Shift Changes

A high percentage of accidents historically occur shortly after a shift change and are often due to a lack of communication. During a shift change, exiting personnel should meet oncoming personnel at the Iockout/tagout device. The oncoming authorized employee should place his/her lock or tag on the energy isolating device before the exiting authorized employee removes his /her lock or tag. If this is not possible, the oncoming authorized employee should place his/her lock or tag on the energy isolating device immediately after the exiting authorized employee removes his/her lock or tag. Exiting employees should inform oncoming employees of any problems or concerns regarding the service and maintenance of machinery or equipment.