Manufacturing Lockout/Tagout Page 1 Manufacturing Industry.

Manufacturing Lockout/Tagout

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Manufacturing Industry


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Management / Supervisory responsibilities

Legal Responsibilities

LOTO Personnel

LOTO Procedures

LOTO Energy Source(s)

TOPICS OF DISCUSSION


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Lock and tag is a two

part process. The lock

disables and the tag is a

warning.

Lockout/ Tagout Process


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MANAGEMENT&

SUPERVISORYRESPONSIBILITIES


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Ethical and moral duty, you have a legal responsibility for safety as a supervisor.

Federal law; supervisors can be held criminally liable for serious injury or death of an employee if proved negligent in their duties.

Fines/prison time for serious and/or willful violations.

Legal Responsibilities


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Fine and Jail Sentencefor

Worker Electrocution

Company fined $140,000

Supervisor sentenced to a year in jail

Company had received notification and several warnings that no work was to be accomplished until a power line crossing the job site was de-energized (locked-out and tagged-out).

Supervisor knowing the hazard, directed an employee to drive a dump truck into the hazard area. Then provided instructions to the employee to raise the truck bed under the energized power line.

The employee was severely burned and died on the scene.

Information Source: Safety 21 OSHA-Compliant Workplace - October 2003


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Develop company policy for implementing lockout/tagout procedures for the control of hazard energy during maintenance operations.

Management Responsibilities

Train authorized and affected employees on proper use of procedures.

Establish written machine-specific procedures to include applying the locks and tags, release, and notification from lockout.


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Supervisors Responsibilities

Ensure initial LOTO training.

Ensure retraining if job assignments change, new machines, control procedures or modifications occurs.

Monitor refresher training.

Enforcement of machine-specific procedures to include applying the locks and tags, release, and notification from lockout.

Check for shortcuts, mistakes, or unsafe work practices.


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LOTOPERSONNEL


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An Authorized Employee

Or Both !

Your Role

You are either an Affected Employee


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Pertains to any employee whose job require them to work in an area where maintenance is performed

Affected Employee

An individual that operates the machinery but does not perform the lockout procedures


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Affected Employee Responsibilities

Report all unusual situation to your supervisor or foreman.

Stay clear of the area as much as possible.

Watch out for others in the area.

Never attempt to assist if your not properly trained.

Never interfere or tamper with a lock or tag.


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An individual who has been properly trained to use lockout/tagout

procedures on a machinery or equipment that is to be serviced.

Authorized Employee


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Authorized Employee Responsibilities Verify the isolation.

Properly plan the job.

Notify all affected employees in the area of work.

Shut down the equipment at the operating controls.

Isolate all energy sources to equipment.

Lock and tag all isolating devices.

Dissipate all stored or residual energy sources.


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Could be Both

An authorized employee and an affected employee may be the same person, when the affected employees’ duties also include performing maintenance or service on a machine or equipment that requires lockout tagout procedure.


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LOTOENERGY SOURCES


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Types of Energy

Electrical Thermal

Mechanical

Chemical Hydraulic

Pneumatic

Could be more depending on machinery type !

Air


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Electrical Energy Hazards

Can cause shock and/or fire


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Hydraulic Energy Hazards

Energy of liquids under pressure- Pressure can cause parts to move- Rapid release can cause injury- Hydraulic fluid can burn you


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Hydraulic values must also be locked out

Next Slide


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Holes drilled in handles to lockout with a chain.


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Boiler

Cold fluids can

cause severe injury

Thermal Energy Hazards

Energy of Heat /Cold

Hot equipment & fluids willburn you


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Pneumatic Energy Hazards

Energy of compressed gasesUncontrolled release can cause injury

Properly vent all systems before starting maintenance


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Six-point hasp used to lockout air valve


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Pneumatic energy can be very dangerous


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Chemical Energy Hazards

Machinery that use any chemicals have energy that can start fires, cause skin burns and generate harmful gases or fumes

Lubricants, Hydraulic fluid, Fuels, Coolants, Solvents


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Mechanical Energy Hazards

Two Types

1. Parts that are still in motion

2. Parts that store energy sources


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Mechanical Energy Hazard

A chipper or hog can remain in motion long after power is locked out

Parts that are still in motion


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Mechanical Energy Hazard

Parts that store energy sources

A plywood press has stored energy by the hydraulic actuators it uses

Position blocks toprevent parts fromFalling or moving


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LOTOPROCEDURES


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The purpose of lockout/tagout is to prevent energy sources from accidentally being released while a machine or equipment is being serviced.

The ultimate goal of lockout/tagout is to protect the safety and health of employees.

Lockout/Tagout Program

“Over 70% of all accidents come from improperly applied procedures or non-compliance”


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OSHA

OSHA requires employers to develop, document, and

implement machine specific procedures for the control

of hazard energy source(s) during maintenance operations.


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LOCKOUT /TAGOUT PROCEDURE

MACHINE NAME AND NUMBER

ENERGY SOURCE(S)

ELECTRICAL CHEMICAL GRAVITY HYDRAULIC

MECHANICAL PNEUMATIC THERMAL OTHER:

LOCKOUT/TAGOUT PROCEDUREELECTRIC:PNEUMATIC:HYDRAULIC:

RESTORING TO NORMAL OPERATIONS

ADDITIONAL SAFETY FEATURES


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Machinery Lockout/Tagout

7-step process

2. Shut down equipment

3. Isolate all energy sources 4. Install Locks and Tags

5. Verify stored energy shut-down

6. Verify equipment isolation

7. Release from Lockout

1. Prepare for shutdown


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Step 1Prepare for shutdown

Must know what energy sources associated with equipment

Electrical

Hydraulic

Pneumatic

Thermal

Mechanical

Chemical


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Step 2Shut down equipment

Use normal shutdown procedure


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Step 3Isolate all energy sources

Turn off power at machinery


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Turn off power at machinery at electrical circuit breaker boxes


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Turn off Air and Hydraulic pressure


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Step 4Install Locks and Tags


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Remember to put the key in your pocket – never leave it in the lock


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Step 5Verify stored energy is shut-down

Ensure saw blades have come to a complete stop before removing guards


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Ensure cutter heads are not in motion


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Step 6Verify equipment isolation

Try to restart machinery following normal procedures


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Machinery is now safe for maintenance operations


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Step 7Release from Lockout

Inspect Area and Equipment

Reinstall machine guards

Account for tools and parts

Inform others of equipment start-up


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Conduct annual audits to validate effectiveness of the lockout/tagout procedures

Review procedures annually or when required, especially after an accident has occurred.

Additional lockout/tagout requirements:

Maintain an equipment survey that list the equipmentrequired to have lockout/tagout procedures, type(s) of energy sources, and magnitude of energy.

*


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MACHINERY LOCKOUT

PRACTICES


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Lockout Program Awareness Posters


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Many employers now post their lockout procedures


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Unique IdeaColor coded breaker boxes with drawings to the machines they controls


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Unique IdeaColor coded breaker box with drawings


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Wooden box used to control electrical hazard for machine plug


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Single-point breaker clip used on multiple circuit breaker box

Next Slide


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Single-point breaker clip Next Slide


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SinglePoint

BreakerClip


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Cables used to control electrical hazard for multiple electrical circuit breaker boxes


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Hinged brackets used to control electrical hazard for multiple electrical circuit breaker boxes


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Holes drilled in handles to lockout with a chain.


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Some manufactures install lockoutdevices on their equipment but youmust ensure the device completelyde-energizes the machine.

Next Slide


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Manufactures lockout devices

Next Slide


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Must ensure that manufacture locking devicesare in compliance with OSHA requirements


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UNAUTHORIZED LOCKOUT PRACTICES


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Improper LockoutLocking out control panelsdoes not eliminate powersource to the machinery. Next Slide


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Improper LockoutControl panels are energized

with 110 voltage.Next Slide


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Improper LockoutMost machinery in sawmills

operates on 440 voltage.

Next Slide


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Improper Lockout

Locking out control panelsdoes not de-energize the

machine


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Emergency shutdown switches do not turn off main power source to machine. In fact they have been known to malfunction.


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Emergency shutdown switch withprotective device but no substitutefor locking out electrical circuitbreaker box.


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A hasp positioned over start buttonbut no substitute for locking outelectrical circuit breaker box.


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Some doors and panels are equipped with shut-down switches thatturn off the machinery but do not de-energize the electrical circuits

Next Slide


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Door and panel shut-down switches are not a substitute forlocking out electrical circuit breakers prior to maintenance


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Employee observed clearing wood debris without lockingout machinery or wearing eye protection.


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Employee reaching into machine to clear wood debris without locking out machine or wearing eye protection

Not observing “Danger Signs”


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Q &

A


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1. Employers are responsible for establishing a program consisting of energy control procedures, employee training and an annual inspection of the procedures? True

2. Employers have the option of using either lockout or tagout to control hazard energy sources during maintenance operations? False, lockout devices must be used.

3. Electrical circuit breaker boxes must be labeled as to which machinery item they control to enableemergency shut down of equipment if necessary? True

4. Every form of energy must be isolated and controlled by lockout/tagout and the lockout verified before beginning work? True

5. Lockout/tagout training is only required if the employer feels that the employee may be accident prone or after the employee is involved in an accident that is the result of improper lockout/tagout?

False, initial training, new equipment, and if there has been a change to a procedure

6. The employer must develop and document a company lockout/tagout enforcement policy?

True


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7. It’s okay to restart equipment before you replace machine guards if you have someone watch the open area? False, guards must be in position prior to equipment start-up.

8. An employee may use any available lock, even combination locks when conducting a lockout?

False, only locks identified for lockout purposes. Combination locks are NOT authorized.

9. Lockout/tagout policies describe how a company will conduct the lockout/tagout program,whereas lockout/tagout procedures detail machine specific requirements for placing a machinein a “Zero Energy” state. True

10. You are authorized to share your lock or to barrow one if you and the other employee agree?

False, each authorized employee must have their own lock

Lockout/tagout is a seven-step process that must be followed in exact sequence?

Bonus Question

True


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LOCKOUT/TAGOUTSIGNS

&ACCIDENTS


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Warning signs you may see


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Accidents you may see:


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Do you enforce lockout/tagout ??

This worker wished his supervisor had.

3rd degree burns….failure to deplete hydraulic pressure -- line ruptured.


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Consultative Services

Consultants are available on a request only basis. They will visit a logging site and provide advice on safety programs and required safety standards.

Employers scheduled for consultative review and are not subject to inspection by any other OSHA group.

No penalties are assessed, only a commitment by the employer to heed advice and make any recommended changes.

Requests are treated on a confidential basis. No information is shared with other OSHA groups.


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7 Loss Control Field Reps Field reps carry a variety of safety equipment that is readily available to our Policyholders. 2 Specialized Trainers Chainsaw trainer for on-site and felling tree training. General Industry/Sawmill trainer for on-site OSHA compliance assistance.

Visit their website at www.forestrymutual.com

Additional Logger Services:Other lines of Insurance

On-Site Job Layout Analysis

On-Site Loss Control Assistance

On-Site Safety Meetings

Manufacturing Lockout/Tagout Page 1 Manufacturing Industry.

Documents

lockouttagout procedures

manufacturing industry

affected employee slide

lockout procedures slide

loto personnel slide

authorized employee

control procedures

lockout tagout process