Lockout and tagout devices are handy little tools that help workers performing service or maintenance on equipment or machinery protect themselves against potentially hazardous energy. Without lockouts and tagouts, employees are left vulnerable to injuries and even death caused by unexpected energization (or the release of stored energy). To ensure that these devices are used properly and regularly, employers are tasked with creating lockout tagout training materials that are accessible to all workers.
Lockout Tagout Training: Ensuring Workplace Safety
The responsibility to deliver lockout tagout (LOTO) training to employees isn’t just a formality; it’s a requirement. Standards from the Occupational Safety and Health Administration (OSHA) instruct employers to adopt and implement procedures for LOTO training so that everyone – from outside contract workers to everyday employees - can avoid unnecessary risk.
What is lockout tagout training?
Lockout tagout training is an educational program that aims to teach employees how to correctly use LOTO procedures in the workplace. That means preparing employees to understand, control, and avoid different hazards, such as:
- Electrical energy
- Mechanical energy
- Hydraulic energy
- Chemical energy
- Thermal energy
- Pneumatic energy
There is no single LOTO training option. Employers are free to develop their own training programs based on their facilities and needs.
Why is lockout tagout training important?
It goes without saying that preventing employee injuries is a top priority for any safety procedure. But in addition to keeping workers safe, LOTO training emphasizes teaching employees about the skills they need to properly use and remove energy controls.
Not everyone at risk of encountering hazardous energy is a regular employee, so it’s important that your workers know how to spot warning signs for others, too.
For instance, a contracted electrical worker hired to fix some internal wiring on a piece of equipment may not realize that it’s only been partially de-energized. Knowledgeable employees can step in to help them avoid getting electrocuted – or, at the very least, know what to do if the shock does happen.
How Lockout Tagout Training Works
Employers in charge of LOTO training must first review the standards outlined by OSHA. You can use 29 CFR 1910.147 App A as a guide as you develop procedures for your workplace to ensure they fit minimum requirements and tick the right boxes.
What are the steps involved in lockout tagout procedures?
There are a few different ways to break down the process behind a proper lockout or tagout. These six steps summarize each of the key components of the procedure:
- Prepare. Before you do anything else, assess the situation. Identify relevant procedures and hazards that might apply to the equipment or machinery due for servicing or maintenance. Notify all employees who will be affected by the lockout or tagout and let them know the equipment or machine will be unusable for the time being.
- Shutdown. Next, shut down the machine or equipment in question following proper procedures.
- Isolate. Ensure that the machine or equipment has been properly isolated from all energy sources.
- Lockout or Tagout. An authorized employee can now attach the lockout or tagout device(s) to the machine or equipment. A lockout device should be applied so that it will stay in the “safe” position until moved by the person who set it up. A tag should list the name of the person who performed the lockout/tagout and any other key information.
- Check for Energy. Sometimes, extra hazardous energy may linger in the equipment or machinery. This energy – known as residual energy – needs to be restrained, disconnected, or relieved in some way before moving forward.
- Verify. Double-check that everything has been done correctly and that it’s now safe to work on the machine or equipment. In some workplaces, this step may also involve documenting the procedure and any notes or concerns.
More Tips for Providing Lockout Tagout Training to Employees
You can work with SafeDE to skip the hassle of building a LOTO training program from the ground up. Our program meets OSHA requirements and walks you and your employees through all of the essential details everyone needs to know to stay safe.
But that’s not all – SafeDE also offers comprehensive and free onsite assistance to help you identify potential hazards and ensure your practices meet OSHA regulations. Our consultation services are always voluntary and confidential. Get started requesting a confidential consultation today.
Frequently Asked Questions (FAQs)
Who needs lockout tagout training?
OSHA states that any and all employees who operate, service, maintain, or work in the vicinity of potentially hazardous machinery and equipment must receive lockout tagout training. That includes authorized employees who will actually perform the LOTO procedures and other employees whose jobs may be affected.
What are the OSHA requirements for lockout tagout training?
Specific energy control procedures, periodic inspections, and comprehensive employee training are all key OSHA requirements.
Overall, OSHA requires employers to create, document, and use procedures designed to control hazardous energy in the workplace. Ensuring that all employees have an understanding of and know how to use lockout/tagout systems is also required, which prompts the need for training.
How often should lockout tagout training be conducted?
Lockout tagout training should occur during an employee’s initial job assignment and, ideally, at least annually from there on. Additionally, retraining should happen any time an employee enters a new position or job assignment. New equipment, machines, or hazards in the workplace also warrant retraining.
What are some common mistakes to avoid during lockout tagout procedures?
These seemingly small errors can cause significant problems. Be sure to steer clear of common lockout tagout mistakes like:
- Only partially de-energizing equipment, which can happen due to a lack of knowledge about how the device or energy source(s) function.
- Leaving keys in locks.
- Forgetting or failing to notify all affected employees about locked- or tagged-out equipment and machines.
- Using incorrect or damaged lockout and tagout devices.
- Failing to train employees on the differences and limitations of tagging; tags don’t offer the physical restraint that locks do, so it’s easy for uninformed employees to remove or ignore them.
What are some best practices for lockout tagout program management?
Conducting proper lockout tagout training isn’t the only important task that employers must take on. Management teams should also take care of regular audits and machine or equipment maintenance to ensure everything is up to standard.
Faulty machines and equipment are more likely to cause delays or issues that motivate employees to take shortcuts or overlook safety procedures altogether. This, coupled with the fact that employees may feel overwhelmed by constantly new or changing standards, means that consistent reviews and updates to program management are key.
How can employers ensure employee compliance with lockout tagout procedures?
Employers should regularly inspect their equipment, machines, and employee practices to spot areas of need early. It’s also smart to actively engage employees in the LOTO process so that they feel their voices are heard and concerns understood.
Welcome employees to participate in additional safety training or provide feedback about their experiences so you can make LOTO practices more efficient (and therefore more likely to be followed by everyone). Utilizing disciplinary measures in cases of non-compliance can further drive home the importance of these procedures.
How can employers keep lockout tagout training up-to-date with changing technology and equipment?
To keep your training updated, you’ll first have to keep your technology and equipment updated. Do your best to keep up with industry news, tech advances, and new regulatory updates that affect your industry.
From there, you’ll have the insights you need to know when it’s time to give your training another look. Be sure to incorporate any new practices that come with updated equipment and machines into your training materials. It may be best to retrain employees if the changes are significant.
