LOTO MFG

Manufacturing Lockout/Tagout
Manufacturing Industry
Page 1
TOPICS OF DISCUSSION
Legal Responsibilities
Management / Supervisory responsibilities

LOTO Personnel
LOTO Energy Source(s)
LOTO Procedures
Page 2
Lockout/ TagoutManufacturing
Process Lockout/Tagout
Lock and tag is a two

part process. The lock
disables and the tag is a
warning.
Page 3
MANAGEMENT
&
SUPERVISORY
RESPONSIBILITIES
Page 4
Legal Responsibilities
 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.
Page 5
Fine and Jail Sentence

for
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
Page 6
Source: Safety 21 OSHA-Compliant Workplace - October 2003
Management Responsibilities
 Develop company policy for implementing lockout/tagout procedures

for the control of hazard energy during maintenance operations.
 Establish written machine-specific procedures to include applying

the locks and tags, release, and notification from lockout.
 Train authorized and affected employees on proper use of procedures.
Page 7
Supervisors Responsibilities
 Ensure initial LOTO training.
 Monitor refresher training.
 Check for shortcuts, mistakes,

or unsafe work practices.
 Ensure retraining if job assignments change, new machines, control

procedures or modifications occurs.
 Enforcement of machine-specific procedures to include applying
the locks and tags, release, and notification from lockout.
Page 8
LOTO
PERSONNEL
Page 9
Your Role
You are either an

Affected Employee
An Authorized Employee
Or Both !
Page 10
Affected Employee
An individual that
operates the machinery
but does not perform
the lockout procedures
Pertains to any
employee whose job
require them to work in an
area where maintenance is
performed
Page 11
Affected Employee Responsibilities
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.
Report all unusual situation to your supervisor or foreman.
Page 12
Authorized Employee
An individual who has been properly trained to use lockout/tagout

procedures on a machinery or equipment that is to be serviced.
Page 13
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.

Page 14
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.
Page 15
LOTO
ENERGY SOURCES
Page 16
Types of Energy
Electrical Thermal
Mechanical Air Pneumatic
Chemical Hydraulic
Could be more depending on machinery type !
Page 17
Electrical Energy Hazards
Can cause
shock and/or fire
Page 18
Hydraulic Energy Hazards
Energy of liquids under pressure

- Pressure can cause parts to move
- Rapid release can cause injury
- Hydraulic fluid can burn you
Page 19
Next
Slide
Hydraulic values must also be locked out

Page 20
Holes drilled in handles to lockout with a chain.
Page 21
Thermal Energy Hazards
Energy of Heat /Cold
Boiler
Hot equipment Cold fluids can

& fluids will cause severe
burn you injury
Page 22
Pneumatic Energy Hazards
Energy of compressed gases

Uncontrolled release can cause injury
Properly vent all systems before starting maintenance
Page 23
Six-point hasp used to lockout air valve

Page 24
Manufacturing
Pneumatic energy can be Lockout/Tagout
very dangerous
Page 25
Manufacturing
Chemical Energy Hazards Lockout/Tagout
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

Page 26
Mechanical Energy Hazards
Two Types
1. Parts that are still in motion
2. Parts that store energy sources
Page 27
Manufacturing
Mechanical Energy Hazard Lockout/Tagout
Parts that are still in motion
A chipper or hog can remain in motion long after power is locked out
Page 28
Manufacturing
Mechanical Energy Hazard Lockout/Tagout
Parts that store energy sources
Position blocks to
prevent parts from
Falling or moving
A plywood press has stored energy by the hydraulic actuators it uses

Page 29
LOTO
PROCEDURES
Page 30
Lockout/Tagout Program
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.
“Over 70% of all accidents come from improperly applied

procedures or non-compliance”
Page 31
OSHA requires employers to develop, document, and

implement machine specific procedures for the control
of hazard energy source(s) during maintenance operations.
Page 32
LOCKOUT /TAGOUT PROCEDURE
MACHINE NAME AND NUMBER
ENERGY SOURCE(S)
ELECTRICAL CHEMICAL GRAVITY HYDRAULIC
MECHANICAL PNEUMATIC THERMAL OTHER:
LOCKOUT/TAGOUT PROCEDURE
ELECTRIC:
PNEUMATIC:
HYDRAULIC:
RESTORING TO NORMAL OPERATIONS
ADDITIONAL SAFETY FEATURES
Page 33
Machinery Lockout/Tagout
7-step process
1. Prepare for shutdown 2. Shut down equipment
3. Isolate all energy sources 4. Install Locks and Tags
5. Verify stored energy shut- 6. Verify equipment isolation

down
7. Release from Lockout

Page 34
Step 1 Manufacturing Lockout/Tagout
Prepare for shutdown
Must know what energy sources associated with equipment
Electrical
Hydraulic
Pneumatic
Thermal
Mechanical
Chemical
Page 35
Shut down equipment
Use normal shutdown procedure

Page 36
Isolate all energy sources
Turn off power at machinery

Page 37
Turn off power at machinery at electrical circuit breaker boxes
Page 38
Turn off Air and Hydraulic pressure
Page 39
Step 4
Install Locks and Tags
Page 40
Remember to put the key in your pocket

– never leave it in the lock
Page 41
Step 5
Verify stored energy is shut-down
Ensure saw blades have

come to a complete stop
before removing guards
Page 42
Ensure cutter heads

are not in motion
Page 43
Step 6
Verify equipment isolation
Try to restart machinery

following normal procedures
Page 44
Machinery is now safe for maintenance operations
Page 45
Release from Lockout
Inspect Area and Equipment
Reinstall machine guards
Account for tools and parts
Inform others of equipment start-up

Page 46
Additional lockout/tagout requirements:
 Conduct annual audits to validate effectiveness of the

lockout/tagout procedures
 Review procedures annually or when required, especially

after an accident has occurred.
 Maintain an equipment survey that list the equipment

required to have lockout/tagout procedures, type(s) of
energy sources, and magnitude of energy.
Page 47
*
MACHINERY
LOCKOUT
PRACTICES
Page 48
Lockout Program Awareness Posters

Page 49
Many employers now post their lockout procedures
Page 50
Unique Idea
Color coded breaker boxes with drawings to the machines they controls
Page 51
Unique Idea
Color coded breaker box with drawings
Page 52
Wooden box used to control electrical hazard for machine plug
Page 53
Single-point breaker clip used on multiple circuit breaker box

Next Slide
Page 54
Single-point breaker clip

Next Slide
Page 55
Single
Point
Breaker
Clip
Page 56
Cables used to control electrical hazard for

multiple electrical circuit breaker boxes
Page 57
Hinged brackets used to control electrical hazard

for multiple electrical circuit breaker boxes
Page 58
Holes drilled in handles to lockout with a chain.
Page 59
Some manufactures install lockout

devices on their equipment but you
must ensure the device completely
de-energizes the machine.
Next Slide
Page 60
Manufactures lockout devices
Next Slide
Page 61
Must ensure that manufacture locking devices

are in compliance with OSHA requirements
Page 62
UNAUTHORIZED
LOCKOUT
PRACTICES
Page 63
Improper Lockout
Locking out control panels
does not eliminate power
source to the machinery. Next Slide
Page 64
Improper Lockout
Control panels are energized
with 110 voltage.
Next Slide
Page 65
Improper Lockout
Most machinery in sawmills
operates on 440 voltage.
Next Slide
Page 66
Improper Lockout
Locking out control panels

does not de-energize the
machine
Page 67
Emergency shutdown switches do
not turn off main power source
to machine. In fact they have been
known to malfunction.
Page 68
Emergency shutdown switch with

protective device but no substitute
for locking out electrical circuit
breaker box.
Page 69
A hasp positioned over start button

but no substitute for locking out
electrical circuit breaker box.
Page 70
Some doors and panels are equipped with shut-down switches that
turn off the machinery but do not de-energize the electrical circuits
Next Slide
Page 71
Door and panel shut-down switches are not a substitute for

locking out electrical circuit breakers prior to maintenance
Page 72
Employee observed clearing wood debris without locking

out machinery or wearing eye protection.
Page 73
Not observing
“Danger Signs”
Employee reaching into machine to clear wood debris

without locking out machine or wearing eye protection
Page 74
Q
&
A
Page 75
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 enable
emergency 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
Page 76
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 machine
in 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
Bonus Question
Lockout/tagout is a seven-step process that must be followed in exact sequence?
True
Page 77
LOCKOUT/TAGOUT
SIGNS
&
ACCIDENTS
Page 78
Warning signs you may see

Page 79

Page 80

Page 81

Page 82
Accidents you may see:

Page 83
Page 84
Page 85
Page 86
Page 87
Do you enforce lockout/tagout ??
This worker wished his supervisor

had.
3rd degree burns….failure to deplete

hydraulic pressure -- line ruptured.
Page 88
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.
Page 89
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 Loss Control Assistance
On-Site Job Layout Analysis On-Site Safety Meetings

Page 90

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Manufacturing Lockout/Tagout

Management / Supervisory responsibilities

LOTO Energy Source(s)

Lock and tag is a two

 Ethical and moral duty, you have a legal responsibility

 Federal law; supervisors can be held criminally

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

Fine and Jail Sentence

Company fined $140,000

Supervisor sentenced to a year in jail

The employee was severely burned and died on the scene.

 Develop company policy for implementing lockout/tagout procedures

 Establish written machine-specific procedures to include applying

 Train authorized and affected employees on proper use of procedures.

 Ensure initial LOTO training.

 Monitor refresher training.

 Check for shortcuts, mistakes,

 Ensure retraining if job assignments change, new machines, control

You are either an

Affected Employee Responsibilities

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.

Report all unusual situation to your supervisor or foreman.

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

Authorized Employee Responsibilities

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.

An authorized employee and an affected employee may be the

Mechanical Air Pneumatic

Could be more depending on machinery type !

Energy of liquids under pressure

Hydraulic values must also be locked out

Holes drilled in handles to lockout with a chain.

Hot equipment Cold fluids can

Energy of compressed gases

Six-point hasp used to lockout air valve

Lubricants, Hydraulic fluid, Fuels, Coolants, Solvents

1. Parts that are still in motion

2. Parts that store energy sources

Parts that are still in motion

Parts that store energy sources

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

The purpose of lockout/tagout is to prevent energy

The ultimate goal of lockout/tagout is to protect the

“Over 70% of all accidents come from improperly applied

OSHA requires employers to develop, document, and

LOCKOUT /TAGOUT PROCEDURE

MACHINE NAME AND NUMBER

ELECTRICAL CHEMICAL GRAVITY HYDRAULIC

MECHANICAL PNEUMATIC THERMAL OTHER:

RESTORING TO NORMAL OPERATIONS

ADDITIONAL SAFETY FEATURES

1. Prepare for shutdown 2. Shut down equipment

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

5. Verify stored energy shut- 6. Verify equipment isolation

7. Release from Lockout

Use normal shutdown procedure

Turn off power at machinery