10 Most Common Lockout Tagout Mistakes Employees Make

1. 10 Most Common Lockout Tagout Mistakes Employees Make Ensuring workplace safety is paramount, especially in industries where workers operate heavy machinery. Lockout Tagout is the process that helps in maintaining worker safety during servicing procedures. It refers to a systematic set of guidelines to prevent hazardous energy release accidents. In hazardous industries, where workers are surrounded by risks, even the smallest mistake can lead to life-altering injuries or even fatalities. Understanding these errors can help workers realize the extent of risks associated with ineffective lockout tagout. In this article, we will discuss the ten most common mistakes made by workers during lockout tagout implementation. 1. Not Following Procedures Often, workers try to find shortcuts to the lockout tagout process to get back to production. They tend to skip steps or rush through the process, leaving room for error which can have serious consequences.

2. Tip: Always adhere to the established steps no matter how quickly you want to finish the process. 2. Inadequate Training Workers or employees may take the training process lightly, relying on common knowledge and basic operation skills to implement lockout tagout. This can lead to skipped steps and ineffective lockout due to a lack of proper understanding. Tip: It is the employer's duty to ensure that the employees are trained and re-trained in the relevant procedures to keep the steps fresh in their minds. 3. Using Incorrect Lockout Devices In order to save costs and pass inspections, companies procure cheap lockout tagout devices through local vendors and sellers. Such a lack of quality may cause a worker to lose his life if he relies on an incorrect device to protect him from hazardous energy. Tip: Employees must be provided with relevant and high-quality devices and taught how to use them effectively. 4. Failing to Notify Affected Employees Affected employees are at just as much risk as the authorised employees. To prevent such unexpected accidents, all the staff must be informed about the ongoing procedures beforehand. Tip: Employers must include mandatory communication steps in the established procedures. 5. Poor Maintenance of LOTO Devices Careless use of Lockout Tagout devices may lead to wear and tear, which can harm the authorised employee relying on the device for safety. Tip: Regularly inspect the LOTO devices to ensure their effectiveness. 6. Not Verifying Isolation Verification is an important step to check for any unexpected energy release from the equipment. Tip: All the points must be physically checked to ensure all energy sources have been isolated properly. 7. Ignoring Stored Energy

3. Often, even after shut-off, the equipment may store energy in the form of charged capacitors, tensed springs, hanging items, or more, which may prove to be dangerous for the workers. Tip: Always drain the stored energy, as established by the procedures, before commencing work. 8. Leaving Keys in Locks Applying LOTO padlocks on the lockout device or energy isolating point is pointless if the keys are left in the lock, allowing easy access for unaware staff to turn on the machine. Tip: Keys must be removed from the lock, and the authorised employee who attached the lock is the one responsible for their keys. 9. Removing Someone Else’s Lock Only the authorised employee who placed the lock can remove it, unless in the case of an emergency where the person removing the lock needs the authorised employee's approval. Tip: Enforce strict rules regarding LOTO removal and establish procedures for emergency cases. 10. Not Documenting the Process Failing to properly record maintenance procedures and LOTO use can lead to confusion and mistakes. Tip: Maintain rigid records of ‘who, how & why’ for clarity and compliance. Avoiding these mistakes is crucial for an effective lockout tagout process. The above-mentioned points are just a few of the most commonly made mistakes in LOTO implementation. By sticking to strict protocols and following established procedures, workers can significantly reduce the risks associated with machine maintenance and repair. To further reduce workplace accidents, invest in proper tools, lockout tagout training, LOTO devices, and a machine-specific procedure. This will promote a safe work culture and make the employee responsible for their safety.