When performing maintenance on equipment, lockout/tagout (LOTO) procedures are an important part of your safety procedures. An unexpected startup could result in the injury of a worker, so post and follow LOTO procedures to stay safe!
Document
The first step of a good lockout-tagout procedure is training and documentation! Make sure all personnel understand and agree to comply with safety practices. Document LOTO procedures for each piece of equipment and ensure that it considers all energy sources and includes specific instructions for disconnecting all energy sources and releasing any possible sources of residual energy. Post LOTO procedures on or near equipment to ensure they are accessible.
Prepare
Prepare the site by locating the LOTO procedure for the equipment being serviced and by informing any employee who will be affected by the shutdown. Double check that all energy sources are included on the posted LOTO procedure.
Shut Down
Shut down equipment correctly. If there is a specific order in which shutdown steps must be completed, ensure that they are included in the LOTO procedure for that machine.
Isolate
Disconnect all energy sources to the equipment being serviced, including electric, pneumatic, hydraulic, etc. systems. Release, restrain, or otherwise render safe all potential hazardous stored or residual energy. If a possibility exists for reaccumulation of hazardous energy, regularly verify during the service and maintenance that such energy has not reaccumulated to hazardous levels.
Lockout
The authorized employee will attached lockout devices and/or tags to levers, switches, valves, etc. in the nonoperative (off) position. Lockout devices should ensure that the power cannot be turned on until the lockout is properly removed by the authorized employee. If two or more employees work on the same equipment, each employee should attach his/her lock and/or tag.
Verify
After locking out power sources, ensure that the area is clear of people and then attempt to start the equipment to ensure no unintended motion will occur. Return all switches to the off position to ensure a safe startup later. Verify the isolation and deenergization of the machine.
Inspect
When the work is complete, inspect the site to ensure that the area is clear of tools, materials, and people, and that all guards and safety mechanisms are in place.
Start-up
Upon completion of the inspection, the authorized employee and any other employees who placed the lockout/tagout devices should remove them from the machine. Bring equipment back on line; equipment-specific LOTO procedures should spell out any specific steps or order of steps that must be taken to safely start the equipment.
Notify
Notify affected employees that maintenance is complete and it is now safe to operate the machine.
Additional procedures are needed to ensure that employees leaving during a lockout or coming to work during a lockout know how to safely proceed.
