Evaluate Your Lockout

Management System.

Take This Survey.

A MASTER LOCK SURVEY

A comprehensive lockout management system – a documented program, machine-specific procedures,
effective training, regular audits – is the goal. Its importance cannot be overstated. It builds on itself and
encourages continuous improvement. Yet, with the daily juggling of many responsibilities, many safety
managers are challenged to know where to start or just where to focus. Take this self-assessment survey
to gauge which elements of your lockout management system are strong and effective and where opportunities
for improvements exist to help make your work environment safer.

Assessment
The first step is to assess the current state of your lockout tag-out program – what is working and
where there are gaps. Natural acceptance of the status quo can cause even the best managers to
put it off for another day. Especially when things are going well.

Question 1. Have you assessed your lockout program recently?

O a. I had not thought to do that.
O b. I know we should.
O c. Yes. It’s done.

Written Program
A written lockout program identifies the equipment, procedures, responsibilities, tools, training and
auditing. It should specify the specific machinery; how and where lockout devices are installed; how
stored energy is controlled and de-energized and how isolation can be verified.

Question 2. Do you have written lockout program?

O a. No, not yet.
O b. Have one, but it’s not complete.
O c. Yes, we’re all set.

It could be that you have a written program but is it up to date?

Question 3. Is your lockout program current?

O a. It is old and outdated.
O b. We review it annually.
O c. We improve it frequently.

A MASTER LOCK SURVEY > PG 2 OF 5

Written Procedures
Within your written lockout program there should be procedures for all applicable machinery. It is
important that each individual machine has a written procedure developed specifically for it. You may
have 100 similar machines, but the operating details can vary from machine to machine.

Question 4. Do you have written procedures for all applicable machinery?

O a. No, we don't.
O b. Yes, but only for some.
O c. Yes, every machine has a current procedure.

Tiered Training
Lockout training programs vary from industry to industry and plant to plant. Often this training is
provided only for certain people such as authorized lockout personnel. Experience and case histories
of accidents show that training is essential at all levels: management, authorized personnel and affected
personnel. Each must know their respective roles and responsibilities.

Question 5. Do you conduct training for your lockout program?

O a. Yes, but it’s very generic.
O b. Only for authorized lockout personnel.
O c. Yes, management, authorized personnel and affected personnel are trained.

Even the best training programs are rendered ineffective if what is taught is not followed. Safety
first means that authorized personnel are fully committed to following the written
procedures every time.

Question 6. How well do your authorized personnel follow lockout procedures?

O a. Occasionally.
O b. Whenever they think they need to.
O c. It’s a regular part of their routine.

A MASTER LOCK SURVEY > PG 3 OF 5

Proper Equipment
It is not only important to have the proper lockout equipment but also to have the right amount of
equipment. When there is a limited supply of equipment, a worker may choose between
working unprotected or waiting for the equipment to become available. Under time and production
pressure, he or she may be tempted to take a risk.

Question 7. Do you have enough of the right equipment for all your lockout procedures?
O a. Not sure.
O b. Right equipment, but not enough.
O c. We’ve got it all covered.

Ease of Access
Another important consideration is the accessibility of procedures and equipment. It’s handy to
remember the 15-second rule. A worker should not have to walk longer than 15 seconds to access
the lockout equipment he or she needs. If it takes longer, this can invite poor decision making.

Question 8. Are the proper lockout equipment and procedures available and readily accessible?
O a. I need to evaluate this.
O b. Everything is available, but it's stored in a central location.
O c. Yes, everything is at hand.

Audits
Management needs to be honest with themselves on the question of audits. We are all busy and audits
can seem to be an unnecessary imposition. But the absence of auditing leads to an absence of
information. How can you know if your equipment, training and procedures are adequate if you don’t
ask the questions?

Question 9. Do you perform regular, at least annual, inspections of your lockout procedures, personnel
and written programs?
O a. Not really.
O b. We do, but not often enough.
O c. We meet this requirement.
.

A MASTER LOCK SURVEY > PG 4 OF 5

 And lastly, it’s good to take a systematic approach to following up on audits.

Question 10. How do you implement the findings of your audits?

O a. We struggle with this.
O b. We tackle what’s critical.
O c. We take a continuous improvement approach to our program

How Did You Do?

Mostly A’s Mostly B’s Mostly C’s

IT’S A START ON YOUR WAY YOU’VE GOT IT

Your current program isn’t
meeting basic compliance
requirements. By taking this
self-assessment survey you
have shown you are open to
improvement and ready to
focus your efforts.
.
The self-assessment shows
you’ve got a plan and have
taken action to implement
your lockout program. Now
you can take a few additional
steps to achieve a best-in-class
lockout management system.
Congratulations! You have
built a best-in-class lockout
management system. Your
people are empowered to
protect themselves. Now you
can focus on continuous
improvement.

We Can Help
Together, we make work environments safer. The Master Lock Company offers a comprehensive portfolio
of lockout safety products and professional lockout services. With our unmatched expertise and end-to-end
solutions, we can partner with you to build your customized, best-in-class lockout management system.

Please email us with any questions at safetyconsulting@mlock.com. We will contact you to learn
more about your lockout safety program and determine how we can help.

A MASTER LOCK SURVEY > PG 5 OF 5