Lockout for Safety on the Job Training Program

1. LOCKOUT For Safety on the Job

2. Session Objectives • You will be able to: • Identify types of machine energy • Understand OSHA’s lockout regulations • Identify lockout steps • Understand requirements for locks and tags • Handle situations like group lockout or shift changes • Understand your role during inspections

3. Session Outline • Types of machine energy • OSHA regulations • Lockout definitions and lock requirements • Authorized employees • Lockout steps • Tagout steps and tag requirements • Team lockout and shift changes • Lock and tag removal

4. Types of Energy • Electrical • Hydraulic • Pneumatic • Mechanical • All are dangerous

5. OSHA Standard29 CFR 1910.147 • Requires lockout/tagout to prevent sudden release of energy • Requires specific steps • Requires training

6. Energy Control Program • Written lockout/tagout procedures • OSHA-compliant locks and tags • Regular inspections • Regular training

7. Lockout Defined • Preventing machine part that controls energy from engaging: • Shut off and lock out electricity • Release and lock out energy • Drain and lock out material • Taking extra electrical precautions

8. Lock Requirements • Key or combination • Designated for lockout only • Durable • Standardized • Strong • Identified

9. Authorized Employees • They are trained in: • Specific lockout procedures • Energy recognition • Energy control

10. Affected Employees • They are trained in: • The importance of lockout • The procedures • The reasons they should not perform lockout

11. Other Employees • Other employees are trained to know the importance of lockout • All employees are trained to know never to start equipment or machines that are locked and/or tagged out

12. Retraining • Retraining is required when there are: • New job assignments • New machines, equipment, processes • New energy control procedures • Needs revealed by inspection

13. Retraining (cont.) • Retrained employees must: • Understand new procedures • Understand their responsibilities • Employers must keep written records

14. Lockout Steps • 1. Prepare for shutdown • 2. Notify affected employees • 3. Turn off the machine or equipment

15. Lockout Steps (cont.) • 4. Locate and isolate: • Release spring tension • Relieve trapped pressure • Block or brace any gravity-driven moving parts • 5. Lock out energy

16. Lockout Steps (cont.) • 6. Test the controls • 7. Put controls back to “off” position • 8. Test the circuits • 9. Perform service or maintenance

17. Tagout • Use only when equipment can’t be locked out • Use it as a warning • Remember: Tags don’t prevent start-up

18. Tag Requirements • Tags must: • Meet same requirements as locks • Be standardized • Be easy to read • Be hard to remove • Tags don’t prevent start-up; they are only a warning

19. Tag Requirements (cont.) • Nylon cable ties must: • Not be reused • Attach by hand • Be self-locking • Be hard to remove

20. Team Lockout • Same requirements as individual lockout • One member has primary authority • This person is responsible for safety • Each authorized member uses separate lock and tag • Communication is crucial

21. Shift Changes and Outside Contractors • For shift changes: • Inform employees as they arrive • Provide continuous lockout protection • For outside contractors: • All employers must communicate lockout procedures to all involved • All employees must understand and comply with outside contractor’s energy control program

22. Service Safety • Stay safe when servicing equipment • Don’t: • Reach blindly into areas with energized parts • Plug or unplug equipment with wet hands • Wear metal-conductive items around energized parts

23. Service Safety (cont.) • Do use: • Protective shields, barriers, or insulating materials in confined spaces • Portable ladders with nonmetal side rails • Approved tools in wet areas • Nonconductive head protection • Safety glasses and face protection • Insulated tools

24. Removing Locks • Only authorized employees: • . Make sure employees are a safe distance away • . Remove tools • . Reinstall guards • . Remove locks and tags • . Turn equipment on • . Notify employees that equipment is back in use

25. Removing Locks (cont.) • When original lock/tag installer is unavailable, substitute must: • Be an authorized employee • Verify that original person is unavailable • Let original person know device is removed • Make sure he or she knows before returning to work

26. Inspections • Must be done at least annually • Focus on one machine • Must be done by an authorized employee

27. Inspections (cont.) • Lockout inspections: • Check lockout procedures • Interview authorized employees • Tagout inspections: • Check tagout procedures • Interview authorized and affected employees

28. Inspections (cont.) • Written certification must identify: • Machine or equipment inspected • Date of inspection • Name of the inspector • Names of employees included in inspection • Any problems identified must be corrected

29. Key Points to Remember • Always lock or tag before service or repair • Never ignore or bypass locks or tags • Never remove someone else’s lock or tag • Never use tagout alone if lockout is possible • Always notify employees of lockout activities