manufacturing lockout/tagout page 1 manufacturing industry
TRANSCRIPT
Manufacturing Lockout/Tagout
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Management / Supervisory responsibilities
Legal Responsibilities
LOTO Personnel
LOTO Procedures
LOTO Energy Source(s)
TOPICS OF DISCUSSION
Manufacturing Lockout/Tagout
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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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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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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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Types of Energy
Electrical Thermal
Mechanical
Chemical Hydraulic
Pneumatic
Could be more depending on machinery type !
Air
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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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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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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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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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Turn off power at machinery at electrical circuit breaker boxes
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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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Step 6Verify equipment isolation
Try to restart machinery following normal procedures
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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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Unique IdeaColor coded breaker boxes with drawings to the machines they controls
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Single-point breaker clip used on multiple circuit breaker box
Next Slide
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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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Some manufactures install lockoutdevices on their equipment but youmust ensure the device completelyde-energizes the machine.
Next Slide
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Must ensure that manufacture locking devicesare in compliance with OSHA requirements
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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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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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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