Lockout/tagout (LOTO) is a safety procedure used to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or repair work. The LOTO procedure involves locking and tagging the machine’s energy sources to prevent unexpected startup or release of stored energy. In this toolbox talk, we will discuss the importance of lockout/tagout and the steps to properly execute this safety procedure.
- Importance of Lockout/Tagout
Lockout/tagout is critical to worker safety because it prevents the release of hazardous energy that could cause serious injury or death. Workers who service or maintain machines can be exposed to hazardous energy sources such as electrical, mechanical, hydraulic, pneumatic, chemical, and thermal. LOTO procedures prevent accidents that can occur when machines are not properly locked out and unexpected release of hazardous energy occurs.
- Identifying Energy Sources
The first step in a lockout/tagout procedure is to identify all energy sources on the machine that need to be controlled during maintenance or repair work. Energy sources include electrical, mechanical, hydraulic, pneumatic, chemical, and thermal. Workers must be trained to recognize the potential energy hazards in the workplace and to know how to control them.
- Shutting Down the Machine
Before beginning maintenance or repair work, the machine must be shut down using its normal operating controls. This step is critical to prevent any unexpected start-up of the machine during the maintenance or repair process. After the machine is shut down, the worker must test it to ensure it is inoperative.
- Locking and Tagging the Machine
Once the machine is shut down, the worker must lock and tag each energy source that needs to be controlled. This is typically done by attaching a lockout device to the energy source, which prevents it from being turned on or activated. The worker must also attach a tag to the lockout device, indicating that maintenance or repair work is being performed and the machine must not be started until the lockout/tagout procedure is complete.
- Releasing Stored Energy
After locking and tagging the energy sources, any stored energy must be released. For example, a pressurized hydraulic system may need to be bled of pressure before maintenance work can be safely performed. Stored energy can be extremely hazardous and must be safely released before maintenance or repair work is performed.
- Verifying Lockout/Tagout
Before beginning maintenance or repair work, the worker must verify that all energy sources are properly locked and tagged. This verification step is critical to ensure that the machine cannot be accidentally started during the maintenance or repair process.
- Performing Maintenance or Repair Work
After verifying that the machine is properly locked and tagged, the worker can safely perform maintenance or repair work on the machine.
- Removing Lockout/Tagout Devices
Once maintenance or repair work is complete, the worker must remove all lockout/tagout devices from the machine. This step ensures that the machine can be safely started up again and that it is not accidentally left inoperable due to the lockout/tagout procedure.
In conclusion, lockout/tagout is a critical safety procedure that must be properly executed to prevent accidents and injuries in the workplace. Workers must be trained to identify energy sources, shut down machines, lock and tag energy sources, release stored energy, verify lockout/tagout, perform maintenance or repair work, and remove lockout/tagout devices. Employers must also have a written LOTO program that outlines procedures, training, and periodic inspections to ensure that LOTO procedures are being followed correctly. By following these steps, workers can safely maintain and repair machines without the risk of unexpected startup or release of hazardous energy.
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