We all know of a workplace being a hotbed for injuries and accidents, don’t we? We also want to create a safer environment for ourselves and our colleagues, right?

Well, a safety conscious EHS professional knows what makes for the right thing – an effective lockout/Tagout program! 

Now, I know what you’re thinking – “Wow, this sounds like an overdone subject of conversation!” But hear me out, because having a proper lockout/Tagout program can save lives and prevent workplace mishaps.

Lockout Tagout (LOTO) is a safety procedure that is used to ensure that machines or equipment are properly shut down and cannot be started again while maintenance, servicing, or repair work is being done. Failure to properly implement LOTO can result in serious injury or death, which is why it’s essential for companies to have an effective LOTO program in place.

In this blog, we’ll explore the 7 steps to creating an effective Lockout Tagout program, as outlined by the SPI Health and Safety Blog.

1. Stay Informed: Familiarize Yourself with Lockout Regulations

When implementing a lockout/Tagout program, it’s crucial to be aware of the lockout regulations in your area. These regulations vary by industry and can be different from state to state or even country to country. Failure to comply with these regulations can result in hefty fines or even legal action, not to mention the risk of workplace accidents.

So, make sure to do your research and stay up-to-date on any changes in regulations to ensure that your lockout/Tagout program is fully compliant and effective. Remember, safety first!

Once you have identified all the machinery and equipment that require LOTO, the next step is to develop specific LOTO procedures for each piece of equipment. These procedures should include step-by-step instructions for shutting down, locking out, and tagging out the equipment.

2. List down Equipment & Machinery

Before implementing a lockout/Tagout program, it’s important to survey your facility and identify all machinery and equipment that have the potential to require lockout. This includes anything that uses hazardous energy sources, such as electrical, mechanical, hydraulic, or pneumatic equipment.

By identifying these potential hazards, you can ensure that your lockout/Tagout program is comprehensive and covers all necessary equipment. Skipping this step could result in missed hazards and potential workplace accidents. So, take the time to survey your facility and create a comprehensive list of equipment that needs to be included in your lockout/Tagout program.

3. Mark Energy Sources and Lockout Points

To effectively implement a lockout/Tagout program, it’s crucial to locate and document all start-up areas of energy sources within your facility. This includes mechanical, thermal, stored energy, electrical, pressure, hydraulic, and process control systems. Once you have identified these energy sources, it’s important to post signs and apply labels and tags to warn and identify them. This ensures that employees are aware of the potential hazards and can take the necessary precautions to avoid accidents.

By taking the time to locate and document start-up areas of energy sources and properly labeling them, you can ensure that your lockout/Tagout program is comprehensive and effective.

4. Choose Lockout Controls for Effective Program Implementation

An important step of implementing a lockout/Tagout program, it’s important to identify and document the necessary devices that isolate and lockout energy sources. This includes devices such as padlocks, lockout hasps, circuit breaker lockouts, and valve lockouts. Once you have identified these devices, it’s important to standardize them for various functions to ensure proper identification.

Standardization also helps to streamline the lockout/Tagout process and reduce confusion among employees. By documenting and standardizing the necessary lockout devices, you can ensure that they are readily available for on-site use and that your lockout/Tagout program is effective and efficient.

5. Establish a Program for Lockout Training and Procedures

To ensure the safety of employees and prevent accidents, it is important to develop, standardize, and document the lockout process for each energy source. This includes identifying the level of involvement for each employee, including those who are made aware of the lockout procedures, those who are affected by the energy sources, and those who are required to perform the lockout procedures.

To achieve this, comprehensive training programs and certifications must be provided to employees to ensure that they are fully equipped to handle the lockout process for each energy source. By establishing a clear and standardized lockout process, companies can minimize the risk of accidents and ensure the safety of their employees.

6. Enforce the Lockout Program

Once the lockout/Tagout program has been established and all employees have been adequately trained, it is essential to initiate and enact the program in accordance with the established procedures. This includes posting reminders in areas where lockout/Tagout is required and ensuring that the necessary devices are readily available.

By taking these steps, companies can ensure that all employees are aware of the lockout/Tagout requirements and are equipped with the necessary tools to safely and effectively carry out the procedures. It is crucial to maintain consistency in enforcing the lockout/Tagout program to prevent accidents and maintain a safe work environment for all employees.

7. Review and update the LOTO program regularly

Finally, it’s important to review and update the LOTO program regularly. This includes reviewing any incidents or near misses that have occurred and updating the program as needed to ensure that it continues to be effective.

Once the lockout/Tagout program has been established and all employees have been adequately trained, it is essential to initiate and enact the program in accordance with the established procedures. This includes posting reminders in areas where lockout/Tagout is required and ensuring that the necessary devices are readily available.

By taking these steps, companies can ensure that all employees are aware of the lockout/Tagout requirements and are equipped with the necessary tools to safely and effectively carry out the procedures. It is crucial to maintain consistency in enforcing the lockout/Tagout program to prevent accidents and maintain a safe work environment for all employees.

So to sum up…

A well-executed Lockout Tagout program is like a superhero’s cape – it’s essential for protecting those who work with machinery and equipment. By following the 7 steps outlined above, companies can create a program that is not only comprehensive and easy to understand, but also as powerful as the mighty Thor’s hammer in preventing injury or harm. So, let’s get hammering and prioritize the safety of our employees with a solid Lockout Tagout program!