Machinery: Locking out risk

Lockout Tagout (LOTO) is a physical method of preventing isolated equipment from being accidently or inadvertently reactivated, and providing clear, written warnings indicating the equipment should not be used. It is an effective way of reducing the risks involved when maintaining, cleaning or repairing equipment. For example, if an engineer has moved away from equipment – perhaps to gather different tools or go to lunch – locking and tagging that device means another individual cannot re-activate it.

When working situations involve multiple people, following correct LOTO procedures is even more important. Each worker should use their own lock or key device that only they have access to during the lock out period. This ensures that each worker’s LOTO device can only be removed by them, ensuring equipment can only be reactivated once every worker has finished working. Co-operation and communication are key for a functioning Lockout Tagout procedure.

Planning and implementation 

Implementing a LOTO programme needs to be managed like any other procedure or initiative; time and resources need to be considered in order to make it a success. 

To create a robust programme, businesses need to carry out a detailed audit to identify all equipment requiring energy isolation during maintenance, cleaning or repair activities. The LOTO programme should include an overall policy and implementation plan, describing all processes, responsibilities, training, isolation and restoring procedures and readily accessible Lockout equipment. 

Isolating equipment or machinery with a Lockout device depends on the type of energy and the specific equipment. For instance, on an industrial oven, as well as the electrical power there may also be hydraulic/ pneumatic energy sources, similarly the ambient heat of the oven needs to be dispersed and tested to be safe before commencing work. Some energy sources are not immediately obvious – for instance, potential energy could include suspended weights or compressed springs. All relevant energy points need to be isolated and tested before starting work. The lockout equipment physically stops these points being re-activated, whilst the signs and tags warns everyone else not to use the equipment. 

Signs and Tags 

Lockout signs are designed to notify employees of lockout procedures, equipment positioning and to indicate lockout points and stations. Tags are needed every time a Lockout Tagout device is locked out. They explain why a device has been locked out, who is working on equipment and when it can be restored. Tags and Signs should be easily visible and durable, communicating clearly the machine-specific LOTO procedures. 

Businesses need to identify each employee’s level of involvement within their LOTO programme. The Occupational Safety and Health Administration categorises employees into three groups: those who are made aware of, those who are affected by, and those who perform the lockout procedures.

Current regulations 

Lockout Tagout is a requirement under US legislation and considered a best practice procedure worldwide, as an effective way to protect employees. In the UK the Provision and Use of Work Equipment Regulations 1998 – Regulation 19 (1):  Isolation from Sources of Energy states: 'Every employer shall ensure that where appropriate, work equipment is provided with suitable means to isolate it from all its sources of energy. Every employer shall take appropriate measures to ensure that reconnection of any energy source to work equipment do not expose any person using the equipment to any risk to his health or safety'.

Correct implementation of Lockout Tagout can help reduce downtime and increase productivity. It helps reduce the risk of employer’s exposure to liability and prosecution as well as indirect costs such as repairs to equipment after unexpected start-up.

Product guide

Arco has created a guide demonstrating how basic LOTO locking off steps are an effective way of reducing risks for those maintaining, cleaning or repairing equipment. The guide offers advice on the basics of implementing an effective LOTO programme, information on various types of lockout equipment and details of different keying systems and their uses in different industrial settings. www.arco.co.uk/LOTO