Lockout Tagout Training

1. Lockout Tagout Training Manufacturing Industry

2. TOPICS OF DISCUSSION • Legal Responsibilities • Management / Supervisory responsibilities • LOTO Personnel • LOTO Energy Source(s) • LOTO Procedures

3. Lockout/ Tagout Process • Lock and tag is a two • part process. The lock • disables and the tag is a • warning.

4. MANAGEMENT & SUPERVISORY RESPONSIBILITIES

5. 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.

6. 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 Source: Safety 21 OSHA-Compliant Workplace - October 2003

7. 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.

8. 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.

9. LOTO PERSONNEL

10. Your Role You are either an Affected Employee An Authorized Employee • Or Both !

11. 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

12. 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.

13. Authorized Employee An individual who has been properly trained to use lockout/tagout procedures on a machinery or equipment that is to be serviced.

14. 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.

15. Could be Both An authorized employee and an affectedemployee 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.

16. LOTO ENERGY SOURCES

17. Types of Energy Electrical Thermal Mechanical Air Pneumatic Chemical Hydraulic Could be more depending on machinery type !

18. Electrical Energy Hazards Can cause shock and/or fire

19. Hydraulic Energy Hazards • Energy of liquids under pressure • Pressure can cause parts to move • Rapid release can cause injury • Hydraulic fluid can burn you

20. Next Slide Hydraulic values must also be locked out

21. Holes drilled in handles to lockout with a chain.

22. Thermal Energy Hazards Energy of Heat /Cold Boiler • Cold fluids can cause severe injury Hot equipment & fluids will burn you

23. Pneumatic Energy Hazards Energy of compressed gases Uncontrolled release can cause injury Properly vent all systems before starting maintenance

24. Six-point hasp used to lockout air valve

25. Pneumatic energy can be very dangerous

26. Chemical Energy Hazards Machinery that use any chemicals have energy that can start fires, cause skin burns andgenerate harmful gases or fumes Lubricants, Hydraulic fluid, Fuels, Coolants, Solvents

27. Mechanical Energy Hazards Two Types 1. Parts that are still in motion 2. Parts that store energy sources

28. Mechanical Energy Hazard Parts that are still in motion A chipper or hog can remain in motion long after power is locked out

29. Mechanical Energy Hazard 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

30. LOTO PROCEDURES

31. 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”

32. OSHA OSHA requires employers to develop, document, and implement machine specific procedures for the control of hazard energy source(s) during maintenance operations.

33. 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

34. Machinery Lockout/Tagout 7-step process 1. Prepare for shutdown • Shut down equipment 3. Isolate all energy sources • Install Locks and Tags 5. Verify stored energy shut-down 6. Verify equipment isolation 7. Release from Lockout

35. Step 1 • Prepare for shutdown Must know what energy sources associated with equipment Electrical Hydraulic Pneumatic Thermal Mechanical Chemical

36. Step 2 Shut down equipment Use normal shutdown procedure

37. Step 3 Isolate all energy sources Turn off power at machinery

38. Turn off power at machinery at electrical circuit breaker boxes

39. Turn off Air and Hydraulic pressure

40. Step 4 Install Locks and Tags

41. Remember to put the key in your pocket – never leave it in the lock

42. Step 5 Verify stored energy is shut-down Ensure saw blades have come to a complete stop before removing guards

43. Ensure cutter heads are not in motion

44. Step 6 Verify equipment isolation Try to restart machinery following normal procedures

45. Machinery is now safe for maintenance operations

46. Step 7 Release from Lockout Inspect Area and Equipment Reinstall machine guards Account for tools and parts Inform others of equipment start-up

47. 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. *

48. MACHINERY LOCKOUT PRACTICES

49. Lockout Program Awareness Posters

50. Many employers now post their lockout procedures