CHAPTER-I

1. INTRODUCTION

“Lockout/tagout” refers to specific practices and procedures to safeguard employees from the
unexpected energization or startup of machinery and equipment, or the release of hazardous energy
during service or maintenance activities.1 This requires, in part, that a designated individual turns off
and disconnects the machinery or equipment from its energy source(s) before performing service or
maintenance and that the authorized employee(s) either lock or tag the energy-isolating device(s) to
prevent the release of hazardous energy and take steps to verify that the energy has been isolated
effectively. If the potential exists for the release of hazardous stored energy or for the reaccumulation
of stored energy to a hazardous level, the employer must ensure that the employee(s) take steps to
prevent injury that may result from the release of the stored energy. Lockout devices hold energy-
isolation devices in a safe or “off” position. They provide protection by preventing machines or
equipment from becoming energized because they are positive restraints that no one can remove
without a key or other unlocking mechanism, or through extraordinary means, such as bolt cutters.
Tagout devices, by contrast, are prominent warning devices that an authorized employee fastens to
energy-isolating devices to warn employees not to reenergize the machine while he or she services or
maintains it.

Lockout is defined in the Canadian standard CSA Z460-05 (R2010) "Control of Hazardous
Energy - Lockout and Other Methods" as the "placement of a lock or tag on an energy-isolating
device in accordance with an established procedure, indicating that the energy-isolating device is not
to be operated until removal of the lock or tag in accordance with an established procedure".

Lockout is one way to control hazardous energy. See the OSH Answers Hazardous Energy
Control Programs for a description of the types of hazardous energy, and steps required in a control
program.
In practice, lockout is the isolation of energy from the system (a machine, equipment, or
process) which physically locks the system in a safe mode. The energy-isolating device can be a
manually operated disconnect switch, a circuit breaker, a line valve, or a block (Note: push buttons,
selection switches and other circuit control switches are not considered energy-isolating devices). In
1
most cases, these devices will have loops or tabs which can be locked to a stationary item in a safe
position (de-energized position). The locking device (or lockout device) can be any device that has
the ability to secure the energy-isolating device in a safe position. See the example of the lock and
hasp combination in Figure 1 below.
Tag out is a labelling process that is always used when lockout is required. The process of
tagging out a system involves attaching or using an indicator (usually a standardized label) that
includes the following information:
 Why the lockout/tag out is required (repair, maintenance, etc.).
 Time of application of the lock/tag.
 The name of the authorized person who attached the tag and lock to the system.

1. Why is lockout/tag out important?

Safety devices such as barrier guards or guarding devices are installed on systems to maintain
worker safety while these systems are being operated. When non-routine activities such as
maintenance, repair, or set-up; or the removal of jams, clogs or misaligned feeds are performed, these
safety devices may be removed provided there are alternative methods in place to protect workers
from the increased risk of injury of exposure to the unintended or inadvertent release of energy.
The main method used and recommended to protect workers from risk of harm in these cases is the
use of a lockout/tag out program (LOTO).

2 .What is the purpose of a lockout/tag out program?

 A lockout/tag out program will help prevent:
 Contact with a hazard while performing tasks that require the removal, by-passing, or
deactivation of safe guarding devices.
 The unintended release of hazardous energy (stored energy).
 The unintended start-up or motion of machinery, equipment, or processes.

2
3. What does de-energization mean?
De-energization is a process that is used to disconnect and isolate a system from a source of
energy in order to prevent the release of that energy. By de-energizing the system, you are
eliminating the chance that the system could inadvertently, accidentally or unintentionally cause harm
to a person through movement, or the release of heat, light, or sound.

4.What should lockout procedures and work instructions contain?

The written lockout procedures will identify what needs to be done, when it needs to be done,
what tools are available to do it, who is supposed to do it, and who needs to be notified.
The document should specify:
 The actual specific machine, equipment, or process shutdown and isolation process.
 How and where the lockout devices are installed.
 How stored energy is controlled and subsequently de-energized.
 How the isolation can be verified.

Work instructions will identify how the lockout process is to be carried out in a step-by-step
manner including how stored energy is controlled and de-energized, how isolation can be verified,
and how and where lockout devices are installed. Work instructions are machine, equipment or
process specific and include pictures or images of what is being described.
An organization will have one lockout program document, and as many sets of work
instructions as required, depending on the number of systems that require lockout.

5. What are the basic steps of locking and tagging out a system?
Lockout and tag out processes involve more than putting a lock on a switch. They are
comprehensive step-by-step processes that involve communication, coordination, and training.
Affected person - is an employee whose job requires them to operate a system, or work in an area in
which servicing or maintenance is being performed under lockout/tag out.
Authorized person - is an individual who is qualified to control hazardous energy sources because of
their knowledge, training, and experience and has been assigned to engage in such control.
System - refers to machinery, equipment, or processes.

3
Steps of a lockout/tag out program include:

1. Prepare for shutdown

The authorized person will identify which sources of energy are present and must be
controlled; and more importantly, identify what method of control will be used. This step involves
completing sets of specific work instructions that outline what controls and practices are needed to
lock and tag out a system before performing any activity.

2. Notify all affected employees

The authorized person will communicate the following information to notify affected persons:

 What is going to be locked/tagged out.

 Why it is going to be locked/tagged out.
 For approximately how long will the system be unavailable.
 Who is responsible for the lockout/tag out.
 Who to contact for more information.

3. Equipment Shutdown
If the system is operating it should be shutdown in its normal manner. Use manufacturer
instructions or in-house work instructions. Equipment shutdown involves ensuring controls are in the
off position, and verifying that all moving parts such as flywheels, gears, and spindles have come to a
complete stop.

4. Isolation of system from hazardous energy

The exact written instructions will be specific to that system in the workplace. In general, the
following are used:

Electrical energy - Switch electrical disconnects to the off position. Visually verify that the breaker
connections are in the off position. Lock the disconnects into the off position.
4
 Figure 1: Electrical lockout

Hydraulic and Pneumatic potential energy - Set the valves in the closed position and lock
them into place. Bleed off the energy by opening the pressure relief valves, then closing the airlines.

Figure 2: Hydraulic and Pneumatic lockout

Mechanical potential energy - carefully release energy from springs that may still be
compressed. If this is not feasible, block the parts that may move if there is a possibility that the
spring can transfer energy to it.
Gravitational potential energy - Use a safety block or pin to prevent the part of the system
that may fall or move.
Chemical energy - locate chemical supply lines to the system and close and lockout the
valves. Where possible, bleed lines and/or cap ends to remove chemicals from the system.

5. Dissipation of residual or stored energy

In general, examples include:
 Electrical energy - To find a specific method to discharge a capacitor for the system in
question, contact the manufacturer for guidance. Many systems with electrical components,
motors, or switch gears contain capacitors. Capacitors store electrical energy. In some cases,

5
 capacitors hold a charge in order to release energy very rapidly (e.g., similar to the flash of a
camera). In other cases, capacitors are used to remove spikes and surges in order to protect
other electrical components. Capacitors must be discharged in the lockout process in order to
protect workers from electrical shock.
 Hydraulic and Pneumatic potential energy - Set the valves in the closed position and
locking them into place only isolates the lines from more energy entering the system. In most
cases, there will still be residual energy left in the lines as pressurized fluid. This residual
energy can be removed by bleeding the lines through pressure relief valves. Contact the
manufacturer for more specific details, or if no pressure relief valves are available, what other
methods are available.
 Mechanical potential energy - Carefully release energy from springs that may still be
compressed. If this is not possible, use blocks to hold the parts that may move if the energy is
released
 Gravitational potential energy - If feasible, lower the part to a height where falling is
impossible. If this is not possible, contact the manufacturer for guidance.
 Chemical energy - If available, bleed lines and/or cap ends to remove chemicals from the
system.
6. Lockout/Tag out
When the system's energy sources are locked out, there are specific guidelines that must be
followed to ensure that the lock cannot be removed, and the system cannot be inadvertently operated.
These guidelines include:
 There should be as many locks on the system as there are people working on it. For example,
if a maintenance job requires 3 workers, then 3 locks should be present - each of the
individuals should place their OWN lock on the system

Figure 3: Example of multiple locks on a lockout tag

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7. Verify Isolation
Verify that the system is properly locked out before beginning any work. Verification can take
place in several ways:
 The machine, equipment, or process controls (push buttons, switches, etc.) are engaged or
activated and the result is observed. No result means isolation is verified. Return controls to
safe position (off).
 Visual inspection of:
 Electrical connections to ensure they are open.
 Suspended parts are lowered to a resting position or blocked to prevent movement.
 Other devices that restrain machine or process movement.
 Valve positioning for double block and bleed (for pipes or ducts) - closing two valves of a
section of a line, and then bleeding (or venting) the section of the line between the two closed
valves.
 Presence of solid plate used to absolutely close a line - called line blanking (for pipes or
ducts).
 Any other acceptable method of energy isolation.
 Testing of the equipment:
 Test circuitry (should be done by a certified electrician) - however, equipment with capacitors
needs to be cycled until all energy is drained.
 Check pressure gauges to ensure hydraulic and pneumatic potential energy has been removed.
 Check temperature gauges to ensure thermal energy has been discharged.

 Choose the method that will best ensure that the energy to the system has been isolated
without creating other hazards during the verification.

8. Perform Maintenance or Service Activity

Complete the activity that required the lockout process to be started.

7
9. Remove Lockout/Tag out devices
To remove locks and tags from a system that is now ready to be put back into service, the
following general procedure can be used:
 Inspect the work area to ensure all tools and items have been removed.
 Confirm that all employees and persons are safely located away from hazardous areas.
 Verify that controls are in a neutral position.
 Remove devices and re-energize machine.
 Notify affected employees that servicing is completed.

6. Who is responsible for the lockout program?

Each party in the workplace has a responsibility in the lockout program. In general:
Management is responsible for:
 Drafting, periodically reviewing, and updating the written program.
 Identifying the employees, machines, equipment, and processes included in the program.
 Providing the necessary protective equipment, hardware and appliances.
 Monitoring and measuring conformance with the program.
 Supervisors are responsible for:
 Distributing protective equipment, hardware, and any appliance; and ensuring its proper use
by employees.
 Ensuring that equipment-specific procedures are established for the machines, equipment and
processes in their area.
 Ensuring that only properly trained employees perform service or maintenance that require
lockout.
 Ensuring that employees under their supervision follow the established lockout procedures
where required.
Employees are responsible for:
 Assisting in the development of equipment-specific procedures.
 Following the procedures that have been developed.
 Reporting any problems associated with those procedures, the equipment, or the process of
locking and tagging out.
8
1.2 Statement of the Problem
What are the processes, procedures and policy frameworks that must be taken into
consideration in order to ensure that programs implemented for the control of hazardous energy in
manufacturing industries do not fail?

1.3 Purpose of the Study

The purpose of this study was to determine the factors that must be accounted for so as to
ensure that programs implemented to control hazardous energy in manufacturing industries do not
fail.
1.4 Study Questions
i. The following research questions were addressed by this study:
ii. What are the factors that determine whether programs designed to control hazardous energy
are adequate and effective?
iii. What are the factors that contribute to the failure of control of hazardous energy in industrial
settings without comprehensive LOTO programs?
iv. What are the contributory factors to the failure of control of hazardous energy in industrial
settings with LOTO programs?
v. What strategies need to be put in place to ensure adequate implementation of standard LOTO
programs in manufacturing industries?
vi. What are the means by which the effectiveness of standard LOTO programs be measured?
vii. What are the ways of auditing LOTO programs to ensure they are adequate and that
employees are compliant?

1.5 Significance of the Study

Since OSHA introduced the control of hazardous energy program, the rate of avoidable
incidents that result in injuries and fatalities has not reduced significantly. A significant number of
manufacturing industries are yet to implement LOTO programs while the few that did, have
substandard programs. As a result, this study addressed the following:
i. Critically appraised the methodologies for proper implementation of standard LOTO
programs for manufacturing industries so as to avoid accidents.

9
 ii. Conducted critical gap analysis aimed at determining how the current LOTO program at
XYZ compares with industry best practices
iii. Laid out the benefits of standard LOTO programs to manufacturing industries.
iv. Developed a system of auditing LOTO programs in order to determine adequacy and
measure the effectiveness of standard LOTO programs. v. Emphasized the need for
further formal studies on the effectiveness of standard LOTO programs on the safety
structures of manufacturing industries.

1.6 Limitations of the Study

The scope of this study was limited by the following factors:
i. Inability to access the LOTO programs of other manufacturing facilities in order to
determine local trend as compared to industry best practices.
ii. Limited pool of actual LOTO-related incidents which made a robust review difficult.
iii. Difficulty in accessing records of LOTO-related incidents in industrial settings due to
concerns about regulatory agencies taking them up.
iv. Under-reporting of LOTO-related incidents, especially in manufacturing industries
where the incentive programs for safety are premised on recordable events.

1.7 Methodology
This study critically appraised the processes that were employed in the design and
implementation of programs utilized for the control of hazardous energy in manufacturing companies.
Hence, qualitative research methodology, specifically applying the grounded theory approach, was
used in this study. Information was gathered on the machines and equipment on which lockout/tagout
procedures were performed. Sources of the information and materials used in this study include
checklists, field notes, reflexive journals, surveys, and analysis of documents, materials and
publications on lockout / tagout.

10
 CHAPTER-II

LITERATURE REVIEW

AUTHOR, YEAR
S.
TITLE OF PAPER POINTS OBSERVED
NO OF PUBLISHED
1 Guide to machinery and
Qubec & 2010 Identify machinery and equipment hazards in the
equipment safety workplace
Eliminate or reduce the risk of those hazards causing
harm.
2 Control of hazardous energy
Milieux& Many workplace accidents are caused by machinery that
2008 accidentally becomes activated while being serviced or
maintained.
This accidental activation is called an “uncontrolled
released hazardous energy.” Many of these accidents can
be prevented if the energy sources are isolated, and locked
or tagged out.
3 TheImplementationofHazardou
Qubec&2013 Unintentional activation and releaseofhazardousenergyin
s EnergyControl the courseofservicingor
maintaininganypieceofindustrialized machineor equipment
results in injuries and deaths of personnel on theonehand
and damageto facilities on theotherhand.
This studyconsidered the factors, processes, procedures
and policyframeworks that wererequired to
properlyimplement a standardizedLOTO program in
amanufacturingfacility, usingXYZMedicalInc.,as acase
study.

4 Lockout/tagout Missisaguage&2013 Locking out machinery and equipment prior to servicing

Compliance guide
5 manual Logout &tagout
Wendy wintersteen Tag out is a labelling process that is always used when
or maintenance is an essential element of protecting
employees from the unexpected energization or motion,
start up of the machine or equipment, or release of stored
energy.
To address this issue and to comply with the Michigan
Occupational Safety and Health Act’s (MIOSH Act),
lockout is required. The process of tagging out a system
involves attaching or using an indicator (usually a
standardized label) that includes the following
information:
Why the lockout/tag out is required (repair, maintenance,
etc.).

11
6 Control of hazardus and energy
Farnel Reinforced laminated steel withstands severe physical abuse
sources Hardened steel individually coated for superior rust
production

7 A guide to the controlCherie,k.Benny

hazardus Control energy sources and establishing systametric
logout and tag out
8 Logout and tagout complains
Qubac Control of Hazardous Energy (Lockout/Tagout) Sample
guide Program 21* B Lockout/Tagout Written Program
Evaluation 33* C Lockout/Tagout Compliance Guide: An
Approach to Establishing Written Lockout
9 Safety industrials tools ,
Kelly Are lockout programs in a sample of industries in Quebec
machine and industrials complying with the legal requirements (provincial
processes occupational health and safety regulations) and coherent
with the Canadian standard on lockout, the CSA Z460-05
(2005)

CHAPTER-III

12
 METHODOLOGY

Themethods and procedures used in thestudyareexplained in this chapterunderthe sub-headings that

aredescribed below.

3.1 Methods
Thestudydesignwas quantitative research method with specific application ofthe grounded
theoryapproach (GTA).Information was gathered on themachines and equipment on which
lockout/tagout procedureswereperformed.PertheGTA, sources ofinformation that were used in this
studyincludechecklists, field notes, reflexivejournals, surveys,and analysis of documents, materials
andpublications on lockout / tagout. Thegoal was tocriticallyappraisethe currentLOTO program at
Industry., identify gaps thatexist, and implement activities and procedures that reflected industrybest
practices.

Based on thedocumentsand materials collated,aseries ofactivities and processes that werepivotal to

designing astandardLOTO program werereviewed. Someoftheseinclude:
i. WritingastandardLOTO policyforIndustry.
ii. Selection ofsome equipment forthepilotLOTOprogram
iii. Design oftrainingmanuals and schedulingtrainings for:
a. Personnel in theproduction and maintenancedepartments. b. Managersand supervisors.
c. hands-on demonstration trainings fortechnical personnel
iv. Performinghazard analysis on equipment selected forthepilotLOTO program.
v. Designing LOTO procedures forselectedequipment.
vi. Performingannual and otherscheduled audits ofLOTO program

3.2 Writing a Standard LOTO Policy

As described in theILCIModel ofloss causation,sub-standard policies form part ofthe root causes
oflosses.It thereforebehooves that anypolicyonLockout/Tagout is updated to standard. This
wasachieved byreviewingthecore requirements ofOSHA’s regulation 29 CFR1910.147 which
mandates and regulates thecontrol ofhazardous energy. Achecklist was designed toguideand
13
ensurethat theLOTO policyto bedrafted has keycomponents, someof which are, but not limited to:
(i)definition ofterms, (ii)determination ofauthorized personnel and their responsibilities, (iii)in-class
and hands-on trainings for authorizedpersonnel and their supervisors, (iv)detailed hazard analysis
foreachpieceofequipment, (v)inclusion ofsections that addressed special situations, (vi)pre-emptedand
addressed factors that account forfailureof LOTO programs, and (vi)provided forcontinuous
improvement and regularsafetyaudit

3.3 SelectionofEquipment for thePilotLOTO Program

Theset of equipment thatwas selected forthis studywas that itemized forthepilot LOTO program at
Industry. Theprocessof enrollingthe equipment into thestudywas bystratifiedrandom selection method
through which 40 out of200 piecesof equipment in seven departments in
theplantwereselectedforthestudy.Theselection process took into cognizance the followingtwo
considerations, amongst others:(i)thedepartment in which the equipment wereutilized and
(ii)thestageoftheproduction process in which theequipment wereused

3.4DesignofTraining ManualsforAuthorizedPersonnel
Thetrainingofpersonneland thesupervisors ormanagerswho will enforcecompliance is an integral part
ofimplementing astandard policy.In designingtraining manuals forthe LOTO program, the
followingfactors wereput into consideration (Appendix3.3):
i. Thetrainingmanuals were customized forthespecificpieces of equipmentthat
wereavailableat the facility, inaddition to othergeneralconcepts.
ii. Hands-on demonstrations wereincluded as integral components ofthetraining,
especiallyforpersonnel in theproduction and maintenanceunits.
iii. Separatetrainings wereconducted forsupervisorsand managers in orderto
highlight thebusiness importanceofthepolicybyhighlightingthe following: a.
Thebasicregulatoryrequirements ofLOTO
b. The roles ofmanagers inensuring a closedcommunication loop system
c. Theneed to encourageand, when applicable, enforce employees’ compliance to theLOTO policy.
d. An understandingoftheimportanceoftheLOTOprogram how it contributes to thebottom lineofthe
company.

14
iv. Records of all personnelwho participated in thetrainings weretaken forproper documentation
purpose(Appendix3.4)
v. A checklist was developed forthehands-on part ofthetrainingin orderto ensure that personnel
displayacceptablepractical skills in performing LOTO procedures Also, in view
oftheuniquedifferences in the educational, cultural and professional backgrounds ofthepersonnel at an
egalitarian facilitylikeIndustry., thetrainingmanuals were designed toaddress thesefactors.

3.5 HazardAnalysis andRiskAssessment

A keycomponent ofastandardLOTO program,which is oftentimes omitted, is
performingcomprehensive analysis ofthehazards as well as assessment of risks posed byevery
energysourcein anypieceof equipment. Forthis study, adetailed hazardassessment ofthe selected
equipment wasperformed to determinethe amount of energysources that each pieceof equipment has,
theinherent hazards ofeach energysource, themagnitudeofthe risks posed by each hazard and
theprocedures required to adequatelyde-energize and lock out the equipment. As detailed in
Appendices 3.6 and 3.7, the risk assessment process involvedtheidentification of thesources and types
ofenergy, thecharacterization ofhazards, assessment and quantification of theseverityof risks,
andthedetermination ofacceptablelevel of risk to ‘AsLowAsReasonably Practicable” (ALARP).

3.6 Writing LOTO Procedures

Sequel to the risk assessment process was the risk reduction exercisewhich involved performingaset
ofprocedures, i.e.Lockout/Tagout procedures, which were aimed at adequately
controllinghazardousenergybymitigatingtheidentified risks. Priorto theLOTO process however,
safeshut-downprocedures of equipmentand machines wereperformed (Appendix
3.8).

3.7 Auditing LOTO Program

In orderto ensurethat theLOTO policyis currentand up-to-date,an annual audit ofthe program was
designed toinspect, amongotherthings, that: (i)eachLOTOprocedureis stillrelevant to
thespecificequipment it was designedfor, (ii) appropriateLOTO devices are available forthe
controlofspecificenergysources, (iii)thelist ofpersonnel authorized to performLOTO procedures is

15
reviewedto be current, and (iv)LOTO-related accidents in the previousyearhavebeenreviewedand
appropriatecorrectivemeasures instituted to avert recurrence

3.8 FLOW CHART

16
 CHAPTER IV

4. RESULTS

Quantitative research methodology, usingthegrounded theoryapproach,was used in this studyto design

atemplate fortheimplementationofaprogram forthecontrol ofhazardous energyin
amanufacturingindustry. Checklists wereutilized forthe collection ofdata, information, documents and
materials used in thisstudy.

4.1 Appraisal oftheCurrentLOTO program

A critical appraisal ofthecurrentLOTO programofIndustry.was performed which identified the
following gaps:
v. Inadequatetraining
a. Failureto train all authorized, and not onlymaintenance, personnel inLOTO
b. Trainingprograms that weredevoid ofhands-on demonstrations
vi. Inadequateprocedures
vii. Inferiorityoftagout when used in placeoflockout procedures.
viii. Failureto address all forms of energyand not electrical energyonly.
a. Grosslyoverlookingsecondaryand residual energysources likepneumatic, hydraulic,gravitational,
thermal and otherpressurized energysources.
b. Failureto adequatelycontrol hazardous energysources ofcomplexequipment c.
Overlookinghazardous energydueto lack of comprehensivehazard analysis.
ix. Lack ofeffective communication, especiallyduringshift change.
In thecourseofimplementingastandardizedLOTO program forIndustry., the above gapsweretaken into
cognizance

4.2Written Standard LOTO Policy

17
Usingthechecklist fordesigningaLOTO program as indicated in Appendix3.1, a standard policywas
drafted forthecontrol ofhazardous energyforIndustry.Thekey components ofthepolicy, detailed in
Appendix4.1, includethe following:

a. OverviewoftheLOTO policy. This ensured that thepolicywas in conformitywith OSHA

regulations and inlinewith the company’ssafetyclimate.
b. Definitionofterms. This aspect addressed all thetechnical and conceptual terminologies that
wereused in thepolicyin orderto ensure clarityand prevent ambiguity.
c. Authorized personnel andaffected persons. This segment ofthepolicyaddressed theindividuals in
theorganization who qualified as authorized personnel aswell as thosewho could be considered as
affected persons.
d. Hazardanalysis. Thissection addressed the components of comprehensivehazard analysisand risk
assessment.
e. Special situations. This section addressed threespecial situations that werevery crucial to
thesuccessful implementation and every-dayapplications oftheLOTO policy. These special situations
include:
i. HandingoverofLOTO procedures duringanend or change-of-shift.
ii. Removal ofLOTO devices bypersonnel otherthan thosewho installed them are inadvertentlyabsent
from thesceneorwhen thelock keys aremissingorbroken (Appendix4.1.2).
iii. When LOTO procedures areto beperformed bycontractors.
f. PolicyAudits. This section detailed theneedfor regularauditingofthepolicy, changes that
weretracked overayearperiod and thejustifications for anychangesmadeto thepolicy.

4.3 EquipmentSelectedinto thePilotLOTO Study

Out of200 heavyindustrialized equipment and machines that areused in production at Industry., atotal
of40, representing20%of all heavyindustrialized equipment, were enrolled from seven departments
into theLOTO project through stratified random selection method (Appendix4.2). Table1 below
shows thebreakdown ofthe equipment enrolled into the LOTO project.
Table1

LIST OF EQUIPMENT SELECTED FOR THELOTO PROGRAM

18
 Departments Numberofequipment

Clean Room C 8

CatheterDeptI 5

CatheterDeptII 6

Leads Dept 7

IntroDept 5

Micro DeptII 6

Micro DeptII 3

Total 40

4.4 Training Manuals DesignedforAuthorizedPersonnel

As detailed in Appendix4.3, thekeypoints ofatrainingprogram forLockout /
Tagout(LOTO)werehighlighted to include employer’s responsibilities in providing LOTO trainingfor
employees, writingstandardLOTO procedures for equipment, supplyofadequateLOTO devices and
ensuringthat thework environment is conducive. Otherimportant points highlighted in section
includetheresponsibilities of authorized employees, theirunderstandingofthe procedures
forcontrollinghazardousenergy,andtheneed for annual refreshertrainings and audit
oftheprogram.Forproperrecord keepingand documentation purposes, alist ofpersonnel who
participated in-classtrainingsessions was maintained, as indicated inAppendix4.4. On the otherhand,
Appendices 4.5.1 to 4.5.9 has thedetails of authorized personnel who completed the hands-on
demonstration trainingwith particularemphasis ofthe actual performanceofcritical steps in performing
LOTO procedures.
4.5 HazardAnalysis andRiskAssessment
In orderto reducethe risks to theALARPlevel forthepurposeofperforming Lockout/Tagout procedures,
robust hazardanalysis and risk assessments ofall the equipment and machines wereperformed. A
hazard analysis andrisk assessment checklist was completed for AB-200 Top Mold Press,as
detailed in Appendix4.6. Details of all the energysources that the equipment has, locationsofthe
19
energycontrol points, methods of controllingtheenergysources, the energycontrol devices that
areused,and theappropriatepersonal protective equipment (PPE)that arerequiredareindicated in the
checklist. Special comments orrecommendations as well as thenames ofthedifferent personnel
whocompleted, reviewed andapproved the document were also indicated in the checklist.

4.6 Written LOTO Procedures

TheLOTO procedures designedforeach pieceofequipment werespecificto and tailored afterthehazard
analysesand risk assessments performed on the respectivemachine and equipment. Details ofalockout
procedureon apieceofequipment areindicated in Appendix4.8

4.7 Audited LOTO Program

PerthepolicyofIndustry.theLOTO program will be audited on annual basis. As indicated in
Appendix4.9, the audit is designed toreflect the following:

 EachLOTO procedureisstill relevant to thespecific equipment it was designedfor

AppropriateLOTO devices areavailableforthecontrol ofspecificenergysources
 Thelist ofpersonnel authorized to performLOTOprocedures is reviewed to
becurrent,andLOTO-related accidents in thepreviousyearhavebeen reviewedand appropriate
correctivemeasures instituted to avert recurrence.

CHAPTER V

5. CONCLUSION
To ensurethat aproperlyimplemented program tocontrol hazardous energyin a manufacturing
companydoes not fail dueto existenceofgaps, astandardized policyframe works must bedrafted,
comprehensiveprocessesput in placewhiletheLOTO procedures must be adequate. Processes such as
areview ofthe current program coupled with comprehensive risk and hazard assessment
wereinstrumental to identifyingexisting gaps and in determining factors that causeLOTO programs to
20
fail. Conversely, processes suchas adequateLOTO training programs forpersonneland
designingcomprehensiveLOTO procedures werehelpful in closing thegaps identified and inthedesign
ofa robustLOTO policy.

CHAPTER VI

6. REFERENCE
1. L’organisationmunicipaleetrégionale au Québec en 2010 [Municipal and regional organization in
Québec in 2010] [Internet]. Montréal, QC, Canada: Ministère des Affaires municipales, des
Régionset de l’Occupation du territoire; 2010. Retrieved July 16, 2013, from: http://collections.banq.
qc.ca/ark:/52327/bs2007465.

2. La CSST invite les milieux de travail à cadenasser [The CSST invites workplaces to apply lockout]
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[Internet]. Montréal, QC, Canada: Commission de la santé et de la sécurité du travail (CSST); 2008.
Retrieved July 16, 2013, from: http://www.csst.qc.ca/ salle_de_presse/actualites/2008/Pages/29_
septembre_cadenassage.aspx.

3. Regulation respecting occupational health and safety (chapter S-2.1, r. 13). Québec, QC, Canada:
Gouvernement du Québec; 2013. Retrieved July 16, 2013, from: http://
www2.publicationsduquebec.gouv.qc.ca/dynamicSearch/telecharge.php?type=3&file=/S_2_1/S2_1R
13_A.HTM.

4. International Organization for Standardization (ISO). Safety of machinery—general principles for

design—risk assessment and risk reduction (Standard No. ISO 12100: 2010). Geneva, Switzerland:
ISO; 2010.

5. Canadian Standard Association (CSA). Control of hazardous energy: lockout and other methods
(Standard No. CSA Z460- 13). Mississauga, ON, Canada: CSA; 2013

6.Program elements and outlines general lockout rules and procedures [Kelley, 2001]. Examples of
written lockout programs are given in [CSA Z460-05 (2005), Kelley (2001), ANSI/ASSE Z244.1
(2003), ASP Imprimerie (2003) and ASSPPQ/ASSIFQ (2001)].

7. which was effective May 25, 1993. This standard adopts OSHA 1910.147 by reference and
revoked previous lockout provisions in MIOSHA General Industry Safety Standards Part 1, General
Provisions

8. Depart
ment of health and safety human services public health service in sep 1983DHHS (NOSH)
publication no 83-125 J. Donald Millar 22(D) (2) of the health and safety

9.To comply with OSHA's Lockout/Tagout Standard (29 CFR 1910.147), Iowa State University and
all aected departments must meet the following minimum general requirements develop written,
equipment-specic lockout procedure [Wendy Wintersteen]

10.https://brieserconstruction.sharepoint.com/Safety/SAFETY/Safety Manual/Brieser Safety

Manual-Master/SECTION 12 LOCKOUT TAGOUT PROCEDURE/Brieser SH&E Manual-Sect 12

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Control of Hazardous Energy Lockout Tagout 12-06-16

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