View all topics

Lockout/Tagout to Prevent Equipment Activation

Caught In Between | OSHA Fatal Four

The Problem

Unexpected equipment activation is one of the leading causes of workplace injuries and fatalities. Without proper lockout/tagout (LOTO) procedures, employees are at risk of severe injuries, including amputations, electrocution, or being caught in machinery. Today, we’ll discuss how lockout/tagout procedures protect you and ensure that equipment is de-energized and safe to work on.

Identify the Hazards

  • Unexpected Activation:

    Machines starting during maintenance or repair due to failure to isolate power.
    ‍
  • Stored Energy Release:

    Hazardous energy, like pressure, electrical charge, or mechanical force, releasing suddenly.
    ‍
  • Improper Tagging:

    Incomplete or unclear tagging of machines, leading to accidental re-energization.

These hazards are preventable if proper lockout/tagout procedures are followed.

Safety Practices and Preventative Measures

To mitigate these hazards, always follow these steps:

  1. Understand When to Use LOTO:

    • Use lockout/tagout whenever performing maintenance, servicing, or cleaning on equipment that could start unexpectedly or release hazardous energy.
  2. Follow LOTO Procedures:

    • Notify All Affected Employees: Inform everyone in the area that equipment will be shut down and locked out.
    • Power Down Equipment: Turn off the machine using its normal controls.
    • Isolate the Energy Source: Disconnect the equipment from its energy source (e.g., electrical, hydraulic, pneumatic).
    • Apply Locks and Tags: Securely attach locks and tags to ensure the equipment cannot be turned on. Tags must clearly indicate the reason for the lockout.
    • Release Stored Energy: Safely release any residual or stored energy (e.g., bleed pressure from a hydraulic line or discharge capacitors in an electrical circuit).
    • Verify Isolation: Test the equipment to confirm it is fully de-energized before starting work.
  3. Never Deviate from Procedure:

    • Do not bypass, remove, or ignore locks and tags unless you are the authorized person performing LOTO removal.
  4. Properly Remove Locks and Tags:

    • After the work is completed, ensure all tools and personnel are clear, then remove the lockout/tagout devices following company procedures.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

E.g. In one incident, a maintenance worker suffered fatal injuries when a machine unexpectedly started during servicing. The worker failed to lock out the equipment properly, and another employee unknowingly re-energized the system. This tragedy underscores why strict adherence to lockout/tagout procedures is vital.

Employee Responsibilities

  • Follow LOTO procedures every time you service or maintain equipment.
  • Use locks and tags provided by the company—never use makeshift devices.
  • Confirm all energy sources are fully isolated before starting work.
  • Report any defective or missing LOTO devices immediately.

Employer Responsibilities

  • Provide proper LOTO training and equipment.
  • Ensure that written LOTO procedures are accessible and specific to the equipment.
  • Regularly audit and update LOTO programs to address any gaps.
  • Replace worn or damaged locks and tags promptly.

Discussion & Questions

  • "What challenges have you faced when implementing lockout/tagout procedures?"
  • "Have you seen or experienced incidents involving unexpected equipment activation?"
  • Allow employees to share their experiences or raise concerns.

Commitment/Action Plan

Starting today, let’s commit to using lockout/tagout procedures for every applicable task. If you’re ever unsure about the process or equipment, stop and ask your supervisor for clarification. Remember, safety starts with each one of us.

Wrap-Up

Lockout/tagout is one of the most effective ways to prevent serious injuries on the job. Following these procedures isn’t just about compliance—it’s about going home safely at the end of the day. Thank you for your attention and dedication to safety.

Standards Overview

  • OSHA’s Control of Hazardous Energy Standard (1910.147) requires employers to establish and enforce lockout/tagout procedures.
  • These regulations are designed to prevent the accidental release of hazardous energy during servicing or maintenance of machines and equipment.
OSHA Occupational Safety and Health Administration

Legal Disclaimer

This toolbox talk is provided for informational and educational purposes only. It is not intended to be a substitute for professional legal, safety, or regulatory advice. The information presented is based on best practices and general industry standards but may not apply to all workplace situations.
‍
It is the responsibility of the employer, supervisors, and workers to ensure compliance with applicable federal, state, and local laws, regulations, and standards. The authors, presenters, and distributors of this toolbox talk assume no liability for the use or application of the information provided.
‍
Participants are encouraged to consult appropriate legal, safety, or regulatory professionals to address specific concerns or questions. Always follow your organization's policies and procedures for workplace safety and hazard mitigation.

All Rights Reserved Site App Pro 2024