Example of a Lockout Tag
Thomas L. Bean, in collaboration with Timothy W. Butcher and Timothy Lawrence
Recently, an employee was cleaning the unguarded side of an operating saw. The employee was caught in the moving parts of the saw, pulled into a nip point between the saw blade and the idler wheel and fatally injured. This accident was caused by the failure to shut down or turn off the equipment to perform maintenance. If the employee had used a lockout/tagout procedure, he would still be alive today.
The Control of Hazardous Energy Source Standard (29 CFR 1910.147), which is more commonly known as the Lockout/Tagout Standard, is a Federal Occupational Safety and Health Administration (OSHA) program. It is designed to prevent the unexpected start-up, or energizing, of machinery and equipment during service and maintenance operations that could cause injury to employees. It is also designed to prevent the release of stored energy that could cause injury to employees. Industry has been obligated to comply with the Lockout/Tagout Standard since January 3, 1990.
The lockout standard applies if:
Minor tool changes, adjustments and other minor service activities that take place during normal production are not included in the Lockout/Tagout Standard provided they are: 1) routine, repetitive and integral to the use of the equipment; and 2) performed using alternative measures that provide effective protection for the employee.
Most people immediately think of electricity as a potentially hazardous energy source. There are other sources of energy, though, that can be just as hazardous. These energy sources include thermal, chemical, pneumatic, hydraulic, mechanical and gravitational. It is important to remember that all sources of energy that have the potential to unexpectedly startup, energize or release must be identified and locked, blocked or released before servicing or maintenance is performed.
In order to comply, a company must prepare a written Lockout/Tagout Program that includes the scope, purpose, authorization, rules and techniques to be used to control hazardous energy. Training must also be provided to all employees who are affected by the lockout/tagout procedures. The written program must include the following items:
Example of a Lockout Tag
The basic equipment needed for a lockout/tagout procedure includes locks and/or tags. Locks are to be used whenever possible. Both locks and tags must clearly indicate the identity of the employee who applied the device. This provides positive identification about who is servicing the machinery and equipment. The identification will also indicate who may not have finished working in a multiple lockout/tagout situation. The locks and tags must be durable enough to withstand the environment in which they will be used. Information on the locks and tags must remain legible. Locks must be substantial enough to prevent removal without the use of excessive force. Tags must be substantial enough to prevent accidental or inadvertent removal. Both locks and tags are to be standardized by color, shape or size. Tags must have a standard print and format. If an energy isolating device is not capable of being locked out, a tag is to be used. An energy isolating device is simply a mechanical device that physically prevents the transmission or release of energy.
All machinery and equipment must be designed to accept a lockout device when major replacements, repairs, renovations or modifications of machinery or equipment are performed, or whenever new machinery or equipment is installed. An audit should be conducted on all machines and equipment to identify all potentially dangerous energy sources and all energy isolating devices. By doing this, employers will be able to establish all appropriate lockout/tagout procedures.
Two types of personnel are directly affected by the Lockout/ Tagout Standard: Affected Employees and Authorized Employees. OSHA defines an Affected Employee as an employee whose job requires him/her to operate or use machinery or equipment on which servicing or maintenance is being performed under a lockout/tagout procedure or whose job requires him/her to work in an area in which servicing or maintenance is being performed under a lockout/tagout procedure. OSHA defines an Authorized Employee as an employee who implements a lockout/tagout procedure on machinery or equipment in order that servicing or maintenance may be performed. Often, an authorized employee and an affected employee may be the same person.
An actual lockout/tagout procedure is simple and straightforward. There are two phases to the procedure.
This example of the lockout/tagout procedure is used when only one person is performing service or maintenance on machinery or equipment and when no testing or positioning of the equipment is required.
In a multiple lockout/tagout procedure, each person working on the machinery or equipment must place a lock or tag on the energy isolating device. If the energy isolating device will not accept multiple locks or tags, a hasp (a multiple lockout device) may be used. The locks or tags must be placed in such a way that energy cannot be restored to the machinery or equipment until every lock or tag is removed. As each employee involved no longer needs to maintain his/her lockout/tagout protection, that employee removes his/her lock or tag. The employee attaching the lock or tag is the only person authorized to remove the lock or tag.
Before a machine can be placed in service, the positioning of parts is sometimes required. The following procedure should be followed when testing or positioning machinery or equipment during service and maintenance:
Each energy control procedure must be inspected at least annually to ensure that the requirements of the Lockout/Tagout Standard are being met. Each inspection will be conducted by an authorized employee other than the employee who normally uses the machinery or equipment or performs the lockout/tagout procedure. After each inspection, the employer must certify that the inspection has been completed.
All employees working in an area requiring lockout/tagout procedures must be trained. Training must include:
Training must occur whenever there is a change in job assignment, a change in machinery or equipment, an energy control procedure change or a change in a process that presents a new hazard. Retraining is conducted whenever the employer believes that employees' knowledge of energy control procedures is inadequate and as part of the annual inspection.
When outside personnel, such as contractors, are on-site and engaged in activities that require compliance with the Lockout/Tagout Standard, the on-site employer and the outside employer must inform one another of their lockout/tagout procedures. It is the responsibility of the on-site employer to ensure that his/her employees understand and comply with the methods of the other's lockout/tagout procedures.
A high percentage of accidents historically occur shortly after a shift change and are often due to a lack of communication. During a shift change, exiting personnel should meet oncoming personnel at the lockout/tagout device. The oncoming authorized employee should place his/her lock or tag on the energy isolating device before the exiting authorized employee removes his/her lock or tag. If this is not possible, the oncoming authorized employee should place his/her lock or tag on the energy isolating device immediately after the exiting authorized employee removes his/her lock or tag. Exiting employees should inform oncoming employees of any problems or concerns regarding the service and maintenance of machinery or equipment.
The checklist below has been developed to help you comply with the Lockout/Tagout Standard.
This standard covers the servicing and maintenance of machines and equipment where the unexpected energizing, start-up or release of energy could cause injury to employees. The standard establishes minimum performance requirements for the control of such hazardous energy during normal servicing and/or maintenance of machines and equipment. However, this standard does not apply to construction, agriculture and maritime employment; installation under the exclusive control of electrical utilities; exposure to electrical hazards from work on, near or with conductors or equipment in electrical utilization installation; and oil and gas well drilling and servicing.
Although there are exemptions to these standards, they may not eliminate your personal liability. Obtain legal advice if you have questions about liability.
The Control of Hazardous Energy Source Standard requires employers to isolate machinery and equipment from its energy sources and to lock or tag them before service or maintenance is performed. The standard also requires that all employees be trained in the company's lockout/tagout policies and procedures.
Dr. Thomas L. Bean and Mr. Timothy J. Lawrence wish to acknowledge Dr. Curt C. Hassler and Mr. Herman C. Sims, et al., for the initial development of this fact sheet material.
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