This presentation covers the basic concepts of lockout and tagout (LOTO).

This presentation does NOT cover performing a specific lockout/tagout

procedure.

1

LOTO is an OSHA-required program for all business where the risk of injury

exists during machine service and maintenance, installation and set-up,

adjustment and other activities.

LOTO was created to ensure that machine operators and maintenance

personnel are protected from unexpected:

• Energization

• Startup of equipment

• Release of hazardous energy.

The LOTO standard has specific training requirements for all employees in a

machine shop. Records of training must be kept.

2

This is an example of a lockout kit. It includes:

• A lock. The lock should be easily recognizable and have only 1 key

issued to the owner of the lock.

• A tag. The tag should be specific to the employee trained and authorized

to use it.

• A locking device. The device shown is just one example of the locking

devices available.

3

Hazardous energy refers to energy that is released unexpectedly from a

machine. This is the energy that we control through LOTO.

Any type of energy is potentially hazardous!

Common forms of hazardous energy include:

• Electrical

• Gravitational

• Hydraulic

• Kinetic – such as residual movement in moving parts

4

Anyone working on machinery may be exposed to injuries from energy

surges, machine startup, or release of energy stored in the equipment.

Based on national data, in metal fabrication:

• 10% of fatalities are due to failure to use LOTO procedures

• 15% of serious trauma cases are also LOTO-related

5

The LOTO standard designates two classes of employees: “authorized” and

“affected”

An “authorized” employee:

• Must receive special training in LOTO procedures

• Is allowed to lock out a piece of equipment

• Is allowed to restart a locked out machine

• Has a LOTO lock with only one key

• Has a LOTO tag with their picture and name on it

6

An “affected” employee:

• Has no LOTO responsibilities

• Must recognize when LOTO is in progress

• Is not allowed to remove locks and tags

• Is not allowed to bypass locks and tags

YOU will be an “affected” employee unless trained in LOTO.

7

OSHA requires that all “authorized” and “affected” employees receive

training.

Employers must provide this training.

Re-training must be provided when there is a change in:

• Job assignment

• Machinery or processes that present a new hazard

• Energy-control or LOTO procedures

8

When a LOTO procedure is about to be implemented on a piece of

equipment, the affected employee will be notified that:

• LOTO is about to occur.

• The machine cannot be operated until the person who locked it says it is

safe to do so.

9

Do not use a machine from the time you are told it is being shut down until

you are told it is safe to use.

If you see a lock or a tag:

• Do not bypass it.

• Do not try to remove it.

10

If you are not sure whether a piece of equipment is locked or tagged, be sure

to ASK.

11

This is an example of a lockable disconnect. You will notice this on most

newer machines.

Lockable disconnects should be:

• In plain view from your workstation

• Present for each source of energy powering the machine

If you notice that a disconnect was missed while a LOTO procedure is set-up

or in progress, speak up!

12

When the LOTO procedure is completed, you – the “affected” employee will

be notified that:

• The equipment will be restarted. You must be safely positioned out of

harm's way during reactivation.

• All LOTO devices have been removed.

The “authorized employee” must test the equipment to be sure it is safe,

before YOU can use it.

13

Ideally LOTO procedures should be posted on or near each piece of

machinery.

14

The photo on the left shows a press blocked open. This is dangerous

practice, because the block of wood can be crushed unexpectedly.

A steel block or other specifically-designed piece should be used instead.

Remember, never attempt to do maintenance work or change dies on a

press without checking that the all energy sources have been locked and

bled (if needed).

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In summary:

� A shop must have a written LOTO program with step-by-step LOTO

procedures for each machine.

� LOTO training must be provided to all “affected” and “authorized”

employees.

� Only “authorized” employees can implement LOTO procedures.

� YOU will be an “affected” employee – unless you receive specific LOTO

training.

� Never remove or bypass locks or tags!

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