Lockout/Tagout (2018)

Summary

The video script emphasizes the importance of lockout/tagout procedures in safeguarding nearly 3.3 million workers from machinery-related injuries and fatalities. It outlines the OSHA standard 29 CFR 1910.147, detailing how to control hazardous energy during maintenance. The script covers training requirements, proper lockout/tagout techniques, and special considerations for group work and contractor scenarios. It stresses the need for compliance to prevent accidents and the critical role of regular inspections and employee retraining.

Takeaways

• 🔐 Lockout tagout is a safety procedure designed to prevent accidental activation of machinery during maintenance, protecting nearly 3.3 million employees each year.
• 🚨 The standard is crucial for compliance, preventing an estimated 120 fatalities and 50,000 injuries annually.
• 🛠️ It applies to all employees working with machinery that requires service or maintenance where hazardous energy could be released.
• 📚 OSHA's 29 CFR 1910.147 standard mandates lockout tagout to control hazardous energy before servicing or maintenance.
• 👷‍♂️ Three types of employees are identified for training: authorized employees, affected employees, and other employees, each with specific training requirements.
• 🛠️ Employers must provide written lockout tagout procedures and ensure they are followed, including isolating machines from energy sources and using locks or tags.
• 🔗 Lockout devices must be standardized, durable, and identifiable, while tagout devices must be clear, tough, and attached with a non-reusable cable.
• 🔄 Annual inspections of lockout tagout procedures by employers are required to ensure compliance and safety.
• 🔄 Special procedures are needed for group lockout tagout, outside contractors, and during shift changes to maintain continuity of protection.
• ⚠️ The script emphasizes the importance of following lockout tagout procedures correctly to prevent injuries and fatalities.

Q & A

What does 'lockout tagout' refer to in the context of workplace safety?

Lockout tagout refers to specific practices and procedures designed to safeguard employees from the unexpected energization or startup of machinery and equipment, or the release of hazardous energy during service or maintenance activities.

Why is compliance with the lockout tagout standard important?

Compliance with the lockout tagout standard is crucial as it is estimated to prevent 120 fatalities and 50,000 injuries each year, ensuring the safety of employees working with machinery that may require servicing or maintenance.

Which standard does OSHA address lockout tagout under, and what is its purpose?

OSHA addresses lockout tagout under the standard 29 CFR 1910.147, 'The Control of Hazardous Energy.' Its purpose is to ensure that machines or equipment are isolated from energy sources and rendered inoperative before servicing or maintenance to prevent accidental activation.

How does the lockout tagout standard protect employees?

The lockout tagout standard protects employees by requiring that before any servicing or maintenance is performed, machines or equipment must be isolated from the energy source, rendered inoperative, and secured with lockout or tagout devices to prevent unexpected energization or startup.

What are the estimated benefits of the lockout tagout standard in industries like automobile and steelmaking?

The lockout tagout standard has reduced fatalities from unexpected activation of machinery in industries such as automobile and steelmaking by 20 to 55 percent since its implementation.

What should be included in an employer's written lockout tagout procedures?

Employers should provide written procedures that outline the scope, purpose, authorization rules, and techniques for the lockout tagout process, including specific steps for isolating, blocking, shutting down the machine or equipment, and the responsibilities for lockout tagout devices.

Who are the three types of employees identified by OSHA for lockout tagout training, and what training should they receive?

OSHA identifies 'authorized employees,' who are trained to lockout or tagout machines; 'affected employees,' who must understand the importance of not using locked out or tagged out machines; and 'other employees,' who need to understand lockout tagout rules but are not part of the process. Each type receives training appropriate to their role.

What is the responsibility of an authorized employee in the lockout tagout process?

An authorized employee is responsible for knowing how machines are powered, recognizing hazardous energy sources, isolating and controlling energy sources, and disconnecting equipment from power sources using lockout or tagout methods.

How often should the lockout tagout energy control procedure be inspected by the employer?

The lockout tagout energy control procedure should be inspected by the employer at least once a year to ensure all employees are following the procedure and to identify and correct any problems.

What are the criteria that locks and tags used in the lockout tagout procedure must meet?

Locks must be durable, standardized within the facility, and strong enough to prevent removal without heavy force or tools. Tags must be standardized, readable in various conditions, tough, and attached with a non-reusable, self-locking nylon cable that can withstand significant pressure.

What steps should be followed when removing lockout tagout devices from a machine?

Before removing lockout tagout devices, the authorized employee must verify isolation, ensure tools are removed, confirm all employees are at a safe distance, and notify all affected employees. If the employee who applied the device is absent, the employer must verify their absence, attempt to contact them, and inform them of the removal upon their return.

Outlines

00:00

🔒 Lockout Tagout: Essential Safety Practices

This paragraph introduces the concept of lockout tagout (LOTO), emphasizing its importance in preventing injuries and fatalities among workers servicing equipment. LOTO is a set of procedures designed to ensure that machinery is isolated from energy sources during maintenance to avoid accidental activation. The paragraph highlights the legal basis for LOTO under OSHA's 29 CFR 1910.147 standard and outlines the estimated benefits of compliance, such as preventing 120 fatalities and 50,000 injuries annually. It also covers the overview of LOTO training, including standards for locks and tags, proper procedures, and special considerations like group LOTO and changes in personnel.

05:02

👷‍♂️ Training and Roles in Lockout Tagout

Paragraph 2 delves into the training requirements for different types of employees involved in LOTO: authorized employees, affected employees, and other employees. Authorized employees are those trained to lockout or tagout machines, while affected employees work with machines under LOTO. Other employees need to understand LOTO rules but are not part of the process. The paragraph stresses the need for retraining when job assignments or procedures change and the annual inspection of LOTO procedures by employers. It also details the criteria for locks and tags used in LOTO, including their durability, standardization, and identification requirements.

10:03

🛠️ Procedures and Guidelines for Lockout Tagout

Paragraph 3 outlines the step-by-step procedures for applying LOTO, including shutting down machines, isolating energy sources, and applying locks and tags. It discusses the release of stored energy and the verification of isolation before work commences. The paragraph also addresses the removal of LOTO devices, the handling of machine testing or positioning, and the coordination between on-site and outside contractors regarding LOTO. It introduces the concept of group LOTO and shift changes, emphasizing the continuity of protection for workers. The paragraph concludes with a reminder of the critical nature of LOTO in preventing injuries and the importance of adhering to the standard without shortcuts.

Keywords

💡Lockout Tagout

Lockout tagout refers to the safety procedures and practices that prevent the accidental or unintentional startup of machinery or equipment during service or maintenance. It is crucial for ensuring worker safety by de-energizing, isolating, and locking out equipment from all potentially hazardous energy sources. In the script, it is mentioned that lockout tagout is required to prevent injuries and fatalities, highlighting its importance in compliance with OSHA standards.

💡Hazardous Energy

Hazardous energy is the potential for physical harm that could be caused by the release of energy such as electrical, pneumatic, hydraulic, or mechanical. The script emphasizes the need to control hazardous energy during servicing or maintenance activities to prevent injuries. It is a central concept in lockout tagout procedures, as it is the energy that needs to be controlled to ensure safety.

💡OSHA

The Occupational Safety and Health Administration (OSHA) is a U.S. government agency responsible for enforcing safety and health regulations in the workplace. In the context of the video, OSHA's standard 29 CFR 1910.147, 'The Control of Hazardous Energy (Lockout/Tagout),' is mentioned as the regulatory framework that mandates lockout tagout procedures to protect employees from hazardous energy.

💡Authorized Employee

An authorized employee is someone who has been trained to understand and execute lockout tagout procedures. They are responsible for shutting down, isolating, and locking out machinery or equipment to perform maintenance or service. The script outlines that authorized employees must know how to recognize hazardous energy sources, isolate and control them, and are the only ones allowed to disconnect equipment from power sources.

💡Affected Employee

Affected employees are those who work in proximity to machinery or equipment that is being serviced or maintained under lockout or tagout. They must understand the purpose and procedures of energy control to appreciate the importance of not using a machine that is locked out or tagged out. The script stresses the need for these employees to be aware of the lockout tagout procedures to ensure their own safety and that of others.

💡Energy Control Procedures

Energy control procedures are the specific steps and methods used to isolate energy sources from machines or equipment to prevent accidental startup during maintenance or servicing. The script mentions that these procedures are essential for ensuring safety and must be followed by all employees involved in or around the machinery that requires servicing or maintenance.

💡Lockout Device

A lockout device is a physical device that locks out energy sources from machinery or equipment to prevent accidental startup. The script specifies that these devices must be durable, standardized, and identifiable to the employee who installs them. They are a critical component of the lockout tagout process, ensuring that machinery remains inoperative during maintenance.

💡Tagout Device

A tagout device is a warning sign used in conjunction with a lockout device to indicate that machinery or equipment has been isolated from its energy source and should not be operated. The script explains that tags must be robust, standardized, and clearly prohibit activation of the machinery. They serve as a visual reminder and warning of the potential hazards associated with the machinery.

💡Group Lockout Tagout

Group lockout tagout refers to a procedure where multiple employees or a team is responsible for the lockout or tagout of a machine or equipment. The script mentions that in such cases, one member of the crew is appointed with primary responsibility for ensuring the safety of all crew members during the lockout process.

💡Shift or Personnel Changes

Shift or personnel changes involve the transition of lockout tagout responsibilities from one group of employees to another, such as from one work shift to the next. The script highlights the importance of continuity of protection during these transitions, ensuring that all employees are aware of the lockout tagout status of machinery and equipment.

💡Outside Contractors

Outside contractors are individuals or companies hired to perform work at a facility, often involving servicing or maintenance of machinery or equipment. The script discusses the need for on-site employers to communicate their lockout tagout procedures to outside contractors and ensure that both parties understand and comply with the established safety measures.

Highlights

Nearly 3.5 million jobs require workers to service equipment, putting them at risk of injury without proper lockout tagout implementation.

Lockout tagout refers to practices and procedures to safeguard employees from unexpected energization or startup of machinery.

Compliance with lockout tagout standards is estimated to prevent 120 fatalities and 50,000 injuries annually.

Lockout tagout standard applies to all employees working with machines needing service or maintenance.

The standard is addressed by OSHA under 29 CFR 1910.147, controlling hazardous energy.

Lockout tagout is required to ensure machines are isolated from energy sources before servicing.

OSHA estimates the lockout tagout standard protects 3.3 million employees each year across 1 million firms.

Employers must provide written lockout tagout procedures outlining scope, purpose, authorization, and techniques.

Authorized employees are trained to know how to lockout or tag out machines and recognize hazardous energy sources.

Affected employees must understand the importance of not using machines that are locked out or tagged out.

Other employees need to understand lockout tagout rules and not attempt to re-energize locked out machines.

Employees should be retrained when job assignments, machines, or energy control procedures change.

Employers are required to inspect lockout tagout energy control procedures at least once a year.

Locks used for lockout procedures must meet specific criteria, including durability and standardization within the facility.

Tags for tagout procedures must be standardized, durable, and include a legend warning of dangers.

Before servicing, authorized employees must shut down machines according to manufacturer procedures and isolate energy sources.

Lockout devices should lock energy isolation devices in the safe or off position; tags are used if locking is not possible.

Stored energy must be released, disconnected, restrained, and rendered safe before work begins on locked out or tagged out machines.

A six-step procedure for hazardous energy control includes preparation, shutdown, isolation, application of lockout tagout devices, release of stored energy, and verification of isolation.

Lockout tagout saves lives and prevents injuries when procedures are followed correctly, emphasizing the importance of safety.

Transcripts

nearly three and 1/2 million jobs

require workers to service equipment

that puts them at great risk of injury

if lockout tagout is not properly

implemented lockout tagout refers to

specific practices and procedures to

safeguard employees from the unexpected

energization or startup of machinery and

equipment or the release of hazardous

energy during service or maintenance

activities compliance with the lockout

tagout standard is estimated to prevent

120 fatalities and 50,000 injuries each

year the lockout tagout standard applies

to all employees who work with or are

around machines that may need to be

serviced or maintained the overview of

this instructional video will cover what

lockout tagout is training of lockout

tagout procedures standards for locks

and tags proper procedures for lockout

tagout and procedures for special

lockout tagout occasions such as with

outside contractors group lockout tagout

and shift or personnel changes

lockout/tagout is a set of safety

procedures designed to reduce the risk

of injury due to accidental activation

of machinery or energizing of electrical

systems during servicing or maintenance

it is addressed by OSHA under the

standard 29 CFR 19 10.1 47 the control

of hazardous energy lockout tagout is

required to ensure that before any

employee performs any servicing or

maintenance on a machine or equipment

where the unexpected energizing startup

or release of stored energy could occur

and cause injury the machine or

equipment shall be isolated from the

energy source and rendered inoperative

OSHA estimates that the lockout tagout

standard protects an average of 3.3

million employees each year at 1 million

firms and that it has reduced fatalities

from unexpected activation of machinery

at facilities in the automobile and

steelmaking industries by 20 to 55

percent in the years since promulgation

all employers should make written

procedures available the procedures

should clearly outline the scope purpose

authorization rules and techniques to be

utilized for the lockout tagout process

procedures should include the following

a specific statement of the intended use

of the procedure written specific steps

for isolating blocking and shutting down

the machine or equipment specific

procedural steps for the placement

removal and transfer of lockout tagout

devices and the responsibility for them

and specific requirements for testing a

machine or equipment to determine the

effectiveness of the lockout device

tagout device and other energy control

measures employers should provide

special training for employees to assure

control of hazardous energy in the

workplace OSHA identifies three types of

employees and the training they should

receive authorized employees are trained

to know how machines are powered and the

procedures necessary to lockout or tag

out the machine or equipment authorized

employees must know how to recognize

hazardous energy sources and what type

and amount of energy they contain they

must also know how to isolate and

control that energy source to prevent

accidents only an authorized employee is

allowed to disconnect the equipment

being serviced or maintained from the

power source or sources using either

lockout tagout or both methods an

employee whose job requires him or her

to operate or use a machine or equipment

on which servicing or maintenance is

being performed under lockout or tagout

or whose job requires him or her to work

in an area in which servicing or

maintenance is being performed is called

an affected employee they must know the

purpose and procedures for energy

control to fully understand the

importance of not using a machine that

is locked out or tagged out an affected

employee becomes an authorized employee

when that employee's duties include

performing service or

that's covered under this standard

employees who work in areas where the

energy control procedures are used but

are not a part of the process are termed

other employees it is important for them

to understand lockout tagout rules and

to not attempt to re-energize machines

that are locked out or tagged out they

also need to learn the limitations of

the tag out devices it is important that

all employees follow the central rule no

one should ever try to start equipment

that is locked out or tagged out

employees should be retrained when their

job assignments change the machines

change equipment or process creates new

hazards and when energy control

procedures change an employee is also

required to be retrained if during an

inspection he or she doesn't appear to

follow or fully understand the procedure

inspection of the lockout tagout energy

control procedure by the employer is

required at least once a year the person

conducting the inspection must not be

involved in using the specific energy

control procedures that are being

inspected during the inspection the

employer or authorized employee checks

to see if all employees are following

the lockout tagout procedure the

inspector reviews lockout

responsibilities with all authorized

employees inspections help find and

correct problems and keep employees safe

inspection documentation should identify

the machine on which the energy control

procedure was inspected the date of the

inspection employees included in the

inspection and the person performing the

inspection

the locks used for a lock out procedure

must meet certain criteria the locks can

either be keyed or combination locks

cannot be used for any other purpose the

locks must be durable enough for the

heat cold humidity or corrosiveness of

the environment in which they will be

used every lock used for the lock out

procedure must be standardized within

the facility in at least one of the

following criteria color size or shape

locks must be strong enough that they

cannot be removed without heavy force or

tools like bolt cutters each lock must

identify the name of the employee who

installs it the tags for a tag out

procedure must meet similar requirements

each tag must have the same print and

format throughout the facility the tags

must be easy to read and understand even

if used in corrosive dirty or damp areas

tags must be tough enough that they can

not be removed easily a nylon cable must

be used to attach each tag the cable

cannot be reusable it must be able to be

attached by hand the cable must be

self-locking and it must be able to

withstand 50 pounds of pressure before

release tags don't lock out energy but

only warn of the dangers tag out devices

should include a legend such as do not

start do not open do not close do not

energize and do not operate the

installers name must be located on the

front of the tag

before the authorized or affected

employee shuts down the machine or

equipment the authorized employee needs

to know the type and amount of energy

the hazards of the energy and the method

and means to control it the machine will

then be shut down according to the

procedures required by the manufacturer

an orderly shutdown must be used to

avoid increased hazards to employees as

a result of incorrect shutdown all

energy the machine utilizes will then be

located and isolated from their sources

the lockout tagout device can then be

placed on the energy isolation device by

the authorized employee the lockout

device should lock the energy isolation

device in the safe or off position if

the isolation device is not capable of

being locked out then the use of a tag

is required the tag should be placed as

close as safely possible to the device

so it will be immediately obvious to

anyone trying to activate the machine or

equipment tag out devices are also

permissible when the employer can safely

prove that the tagout device will

provide employee protection equal to the

lockout device the tag must be placed at

the same point the lockout device would

have been attached the tagout device

must clearly prohibit anyone from

activation of the machine or equipment

stored energy must be released

disconnected restrained and rendered

safe these energy sources include

electrical pneumatic hydraulic

mechanical thermal chemical and the

force of gravity before starting work on

the machine that has been locked out or

tagged out the authorized employee

should verify that the isolation of the

machine or equipment has been achieved

before any locks and tags can be removed

from isolation devices the authorized

employee must follow procedures set

forth by OSHA

the authorized employee must make sure

that tools are removed from the machine

or equipment and all components are

operational all employees should be at a

safe distance from the machine or

equipment each lockout tagout device

should be removed by the employee who

applied the device if the employee who

applied the lockout tagout device is not

present the device can be removed under

the direction of the employer the

procedure to follow in the case of an

absent authorized employee is as follows

the employer needs to verify that the

employee is absent from the facility

reasonable efforts to contact the

employee about the lockout tagout

removal needs to be made the absent

employee will need to be informed that

their lockout tagout device was removed

before they return to work

sometimes lockout/tagout devices are

required to be removed so that the

machine can be tested or positioned the

following sequence of actions should be

followed clear the machine of any tools

and materials used make sure there are

no other employees in the machine or

equipment area remove the lock out tag

out devices from the energy isolation

devices energized and proceed with

testing or positioning deactivate all

systems and reapply energy control

procedures as required by the lockout

tagout procedures from time to time

employers will hire outside contractors

to service the machine or equipment the

on-site employer and outside employer

need to inform each other of their

respected lockout tagout procedures the

on-site employer then needs to make sure

his or her employees understand and

comply with the restrictions of the

outside employers energy control program

in some instances an entire crew or

group will be responsible for lockout

tagout of machines or equipment one

member of the crew needs to be appointed

with the primary responsibility for the

crew and for keeping all members of the

crew safe during lockout each authorized

employee must place their lockout tagout

device on the group lockout device or

lock box when they begin work and remove

it when they stop work on the machine

when shift or personnel changes carry

through from one shift to another

there must be continuity of protection

for off-going employees and oncoming

employees the employees must follow

shift change procedures set by the

employer the lockout tagout procedures

are a method of keeping equipment from

being activated and endangering workers

be sure to follow the six step procedure

for hazardous energy control preparation

for shut down equipment shut down

machine or equipment isolation

application of lockout tagout device

release stored energy verification of

isolation

follow closely the steps for removing

locks and tags clean out any tools or

materials in the machine

make sure all employees are at a safe

distance away and notify all affected

employees that the machine is being

activated lockout tagout saves lives and

prevents injuries

if procedures are followed correctly

never take shortcuts when it comes to

the safety of yourself and others

especially when working with hazardous

energy sources the standard can only

work if it's used correctly every time