AUTHORIZED LOCKOUT TRAINING
What Is Lockout/Tagout? Title 8 Industrial Relations Division 1 Department of Industrial Relations Chapter 4 Division of Industrial Safety Subchapter 7 General Industry Safety Orders Group 2 Safe Practices and Personal Protection Article 7 Miscellaneous Safe Practices Section 3314 - The control of hazardous energy for the cleaning, repairing, servicing, setting-up, and adjusting operations of prime movers, machinery, and equipment.
In a study conducted by the United Auto Workers, 20% of the fatalities (83 of 414) that occurred among their members between 1973 and 1995 were attributed to inadequate hazardous energy control procedures specifically, lockout/tagout procedures. OSHA estimates the Lockout Standard saves 122 lives, 50,000 injuries and prevents 28,000 lost workday injuries each year Workers injured on the job from exposure to hazardous energy lose an average of 24 workdays for recuperation
Energy Control Program Authorized employee A qualified person who locks out or tags out specific machines or equipment in order to perform cleaning, repairing, servicing, setting-up, and/or adjusting operations. Assistant authorized employee An employee trained in authorized lockout procedures, yet requiring the guidance and working under the primary authorized employee.
Energy Control Program Affected employee - An employee whose job requires them to operate or use a machine or equipment on which cleaning, repairing, servicing, setting-up or adjusting operations are being performed under lockout or tagout, or whose job requires the employee to work in an area in which such activities are being performed under lockout or tagout.
When does lockout apply? Cambro s Positive Lockout Standard No. 006 applies during any servicing and/or maintenance activities if an employee is required to remove or bypass a guard or other safety device or if the employee has to put his/her hand at the point of operation. Only authorized employees may perform lockout activities.
What are considered servicing and/or maintenance functions? Repairing Installing Setting up Adjusting Inspecting Modifying Lubricating Cleaning Clearing jams Tool changes Lockout must be considered for each situation. However, certain exceptions are made for minor servicing, maintenance and set-up activities performed during normal production which are routine and repetitive.
Exceptions to subsections (c) and (d): 1. Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations are not covered by the requirements of Section 3314 if they are routine, repetitive, and integral to the use of the equipment or machinery for production, provided that the work is performed using alternative measures which provide effective protection. 2. Work on cord and plug-connected electric equipment for which exposure to the hazards of unexpected energization or start up of the equipment is controlled by the unplugging of the equipment from the energy source and by the plug being under the exclusive control of the employee performing the work.
Lockout Decision Matrix If the operation or task is: Service, maintenance, construction or installation Normal production (unjamming, adjustments, cleaning lubricating changeover, setup.) And: Then: You are exposed to a potentially hazardous energy source You are exposed to a potentially hazardous energy source You must lockout You must lockout OR ensure the equipment has a minimum of 2 *acceptable alternative safety measures
Acceptable alternative safety measures are methods that together provide the same level of safety as lockout. Generally they must be: As foolproof as possible Do not rely on the human element for protection. A minimum of two of the alternate measures must be employed. Alternate measures are: Interlocked guards Manual activation of equipment to restart Exclusive control (for each exposed employee) this includes jog mode. Machine stop / emergency stop buttons Delayed start with audible alarm for start-up of machine
1. Verify all energy sources to the equipment 2. Notify affected personnel in the area that a lockout is being applied to the equipment 3. Shut off the electrical power at the point of operation control
4. Turn off the main disconnect switch and other devices supplying energy to the equipment and physically lock them out. Use the appropriate device. 5. Block or restrain anything that could move or cause movement. 6. Release any stored energy. 7. Try the equipment, machine or process controls.
Verify the energy sources Consider all potential sources: electrical, springs, pneumatic, hydraulic, steam, chemical, thermal, gravitational, mechanical Know the hazard of the energy and how to control it If necessary, review the department lockout procedures
Hey Jesse! I m locking this equipment out! Notify affected people in the area that you will be locking out the equipment
Shut off the electrical power at the point of operational control
Important Points. Never pull a switch while the equipment is under load. Turn your head away from the panel when turning on or off the electrical disconnect. Never remove a fuse instead of using an appropriate disconnect. Keep your lock key in your possession. This is for your protection and exclusive control! When two or more employees work on the same equipment, each must attach a personal lock with tag.
A safety lockout hasp is used when more than one employee needs to work on equipment and it needs to be locked out.
Shut Off Key Switch Lockout Insert is pulled out and locked. Switch Lockout Air Lockout Valve
Cord / Plug Lockouts Lockout not required if single energy source under exclusive control of one employee
Make sure all parts have stopped Make sure all parts have cooled Relieve trapped pressure Injection machine accumulators
Important Point. Return controls to the off position Special Circumstances Remote point of operation - two authorized employees maintain communication Unfamiliar equipment - Authorized employee familiar with equipment must assist
1. Clear tools or other materials from the machine. 2. Inform co-workers about energy isolation device(s) removal and impending startup 3. Ensure all co-workers are clear of the work area 4. Verify power controls are in the off or neutral position 5. Each employee removes his/her own lockout/tagout device 6. Re-energize the equipment
1. Maintenance tasks that require energy 2. Emergency safety lock removal 3. Contractors or Outside employees
There may be tasks that require the equipment to remain energized. These tasks can only be performed by a Maintenance Person, and may include: Trouble shooting Debugging Instrument calibration PLC hook-up Specific machine or control adjustments
EMERGENCY SAFETY LOCK REMOVAL 1. Verify that the employee who applied the lockout device is not at the facility. 2. Make all reasonable efforts to contact the employee to inform him/her that the lockout or tagout device has been removed. 3. Make all reasonable attempts to inform the employee of the removal before he/she resumes work. 4. Inspect the process or equipment to ensure that it is safe to energize. 5. Fill out a Request to Remove Lockout/Tagout Form and submit to Maintenance. Form must be signed by department management. 6. Maintenance verifies that equipment can be energized. 7. Maintenance removes the lock and re-energizes the equipment.
Contractors or Outside Employees Contractors must follow the same lockout rules as Cambro employees.
(1) The procedure shall clearly and specifically outline the scope, purpose, authorization, rules, and techniques to be utilized for the control of hazardous energy, and the means to enforce compliance, including but not limited to, the following: (A) A statement of the intended use of the procedure; (B) The procedural steps for shutting down, isolating, blocking and securing machines or equipment to control hazardous energy; (C) The procedural steps for the placement, removal and transfer of lockout devices and tagout devices and responsibilities; and, (D) The requirements for testing a machine or equipment, to determine and verify the effectiveness of lockout devices, tagout devices andother hazardous energy control devices.
(2) The employer's hazardous energy control procedures shall be documented in writing. (A) The employer's hazardous energy control procedure shall include separate procedural steps for the safe lockout/tagout of each machine or piece of equipment affected by the hazardous energy control procedure.
Need procedures specific for each machine Doesn t need to be complicated Room: Eq. Name: Eq. Number: Energy # of Source Sources Lock Out Location/Procedure Verification Electrical Pneumatic Hydraulic Chemical Gravity Thermal Steam Water PSI
(h) Periodic inspection - The employer shall conduct a periodic inspection of the energy control procedure(s) at least annually to evaluate their continued effectiveness and determine necessity for updating the written procedure(s). (1) The periodic inspection shall be performed by an authorized employee or person other than the one(s) utilizing the hazardous energy control procedures being inspected. (2) Where lockout and/or tagout is used for hazardous energy control, the periodic inspection shall include a review between the inspector and authorized employees of their responsibilities under the hazardous energy control procedure being inspected. (3) The employer shall certify that the periodic inspections have been performed. The certification shall identify the machine or equipment on which the hazardous energy control procedure was being utilized, the date of the inspection, the employees included in the inspection, and the person performing the inspection.
As of 9-10-2013 TEAM 1 OFFICES TEAM 1ST QTR INC RATE 145 Employees TEAM 2 ROTO MOLD 113 Employees TEAM 3 INJECTION 150 Employees TEAM 4 COMP/PERS 62 Employees TEAM 5 COMPOSITE 21 Employees TEAM 6 MAINTENANCE 59 Employees TEAM 7 MOLD SHOP 64 Employees TEAM 8 RECEIVING 20 Employees TEAM 9 QUALITY 29 Employees TEAM 10 LOGISTICS 77 Employees TEAM 10 MTC 59 Employees 0 1 19.0 0 9.5 7.1 0 0.0 0 0.0 2 0 2ND QTR INC RATE 2 5.3 1 4.0 12.5 0 6.2 0 0.0 0 0.0 3RD QTR # INJ INC GOAL GOAL 1 1 4.8 2 10.4 0 5.2 1 5.8 3 4 5.2 0 0.0 0 0.0 1 2.5 0 3 5.1 2 3 4.7 0 1 5.0 0 2 6.9 1 3 5.1 TOTAL= 790 Employees 10 5.3 5 3.8 5 3.7 0 20 36 4.5 INC RATE 0 0.0 0 0.0 0.0 3 10.6 3 10.6 2 10.5 1 4.0 0.0 1 3.2 2.4 0.0 4.6 0.0 0.0 0 0.0 0.0 4TH QTR INC RATE YTD 0 2 1.4 8 6 5.3 4 8 4.7 1 3 4.8
MONTH 2009 2010 2011 2012 2013 JAN 3 4 2 3 3 FEB 0 1 3 1 3 MARCH 2 2 7 1 3 APRIL 2 2 3 2 3 MAY 2 4 1 5 2 JUNE 2 4 1 2 0 JULY 5 2 3 1 2 AUG 2 4 0 5 2 SEPT 1 5 7 6 1 2009 18 OCT 0 2 1 1 2010 23 NOV 0 0 3 2 2011 20 DEC 4 5 3 4 2012 20 TOTAL 23 35 34 33 19 2013 18 This total represents the number of injuries we had each year by the end of August