A lockout presentation that I use in an OSHA 30 hour class.

1. Control of Hazardous Energy
1910.147
Draft 6 27 2016

2. Lockout/Tagout
Need for Lockout - Purpose & Scope of Standard

3. June 2016
• Plainfield IL
• Carlos Rivera, 50, was
caught and pulled
through a steel baler,
authorities said

4. Jun 2016
• “J was not happy to see
their machines with the
doors open and they
were running.”
• The member explained
that they were being set
up and the adjuster (set
up person) was in the
process of adjusting the
paper correctly.

5. January 2015
• A 50-year-old temporary worker
was permanently disabled after a
machine used to package cases of
bottled water onto a pallet for
shipment started up while he
cleared a jam in the machine.
• The worker had been on the job
for 12 days at the Ice River
Springs plant in High Springs, FL.
Is there anything that could jam at your
place?

6. May 2014
• A 17-year-old has the
ability to move his right
arm again, thanks to
surgery performed at
Massachusetts General
Hospital.
• Brett Bouchard severed
his arm just below the
elbow while cleaning a
pasta machine at work.

7. The Need for LOTO
• OSHA: failure to control energy accounts for nearly
10 percent of serious incidents
• Case Studies from the NIOSH report: Guidelines for
Controlling Hazardous Energy During Maintenance
and Servicing reports the following:
Pasta machine

8. May 2014
• Milford IL
• 3 willful at $70,000 each
• The worker was clearing birdseed
from a large industrial mixing
tank.
• The worker’s left hand and arm
were crushed after being caught
in the moving parts of the mixing
machine.
• 147(c)(6)(i)
• 147(c)(7)(i)
• 147(d)(4)(i)
The subsequent investigation
determined Wagner’s failed to lock
out energy sources, which would
have protected the worker from
contact with rotating components of
the machine.

9. 147(c)(6)(i)
• The employer shall
conduct a periodic
inspection of the energy
control procedure at
least annually to ensure
that the procedure and
the requirements of this
standard are being
followed.

10. 147(c)(7)(i)• The employer shall
provide training to
ensure that the purpose
and function of the
energy control program
are understood by
employees and that the
knowledge and skills
required for the safe
application, usage, and
removal of the energy
controls are acquired by
employees

11. 147(d)(4)(i)
• Lockout or tagout
devices shall be affixed
to each energy isolating
device by authorized
employees.
What is missing?

12. Headlines May
2014
• Company ‘willfully ignored’
safety standards in
worker’s death
• Daniel Collazo (left) was
nearly done with his shift
cleaning machines when
other workers heard his
screams.
• Collazo had become caught
in the rotating screws that
blend the hummus and
struggled to free himself as
slowly-winding 9-inch
blades kept turning,
crushing his arms and part
of his head.
The company paid a $540,000
fine to the Occupational Safety
and Health Administration
following Collazo’s death in
2011.

13. Exercise
• May 2014
• Paterson, NJ
• After entering a die
cutting machine to do
maintenance, a worker
employed for 26 years
at was crushed when
the die cutter was
activated by another
employee unaware that
the victim was inside.
CNC die cutting machine
What places could you
be in and others are
unaware you are in the
equipment?

14. First Day
• “A worker’s first day at
work shouldn’t be his
last day on earth,” was
OSHA chief David
Michaels’ reaction to
the work-related death
of Lawrence Daquan
“Day” Davis.
• The 21-year old was
crushed in a palletizer
machine on August 16,
2012 at the Bacardi
Bottling facility in
Jacksonville, FL.
Davis was a temp worker
hired by Remedy
Intelligent Staffing. It was
his first day on assignment
to the Bacardi plant.

15. SIGCASE
• $207,450
• Worker cleaning
equipment in
preparation of set-up
• Equipment not locked
out
• Worker not trained
• No specific procedures
• 5 amputations

16. Wire Drawing
• Severe injuries to
worker setting-up
equipment
• Caught in wire
• Machine either auto
started or
malfunctioned
• No lockout
• Lack of training

17. Baler Operation
• Worker trying to clear
jam
• Baler set on auto-start
and not locked out!
• Worker had no
lockout training
• Injury - worker could
be crushed

18. Cleaning Hazards
• Cleaning a machine is
not supposed to be a
hazard.
• Guards are in place to
prevent exposure to
hazardous motions.
• If guards must be
removed to clean, the
lockout is required.
Cleaning a conveyor is a
common source of death
and amputations. This
conveyor does not have
guards for the rotation of
the horizontal drive shafts.

19. Scope of Standard
• Covers general industry where servicing &
maintenance of machine and equipment can result
in unexpected start up or release of stored energy
that could cause injury

20. Not covered
• Servicing and
maintenance during
normal operations (see
OSHA Standards
subpart O).
• Machine Guarding is
required then!
• Minor tool changes,
adjustments during
normal operations
• Work on cord and plug
equipment

21. Example - Not Meeting Exception
• Grand Rapids MI
• June 27, 2014
• A proposed $558,000 fine
against Grand Rapids
Plastics for safety violations
tied to a worker's death
would be the largest issued
by the Michigan
Occupational Safety and
Health Administration in
more than a decade.
Russell Scharenbroch

22. Definitions
• Lockout.
• Placing a lockout device
on an energy-isolating
device (in accordance
with an established
procedure) ensuring
that the energy
isolating device and the
equipment being
controlled cannot be
operated until the
lockout device is
removed.

23. Definitions
• Lockout device.
• A device that uses a
positive means such as
a lock, either key or
combination type, to
hold an energy-isolating
device in the safe
position and prevent
the energizing of a
machine or equipment.

24. Definitions
• Authorized employee* -
Person who locks or tags
machines & equipment
to perform servicing
• How would this work in
multiple shifts?

25. Lockout - Authorized
need to be trained in
• recognition of applicable
hazardous energy sources
in the workplace
• the type and magnitude
of energy found in the
workplace
• the means and methods
of isolating and/or
controlling the energy

26. Definitions
• Affected employee* -
Person required to use
machines/equipment
on which servicing is
performed under
lockout/ tagout or who
must work in such an
area

27. Lockout - Affected
• All employees who
work in the area where
the energy control
procedure(s) are
utilized need to know
about the prohibition
against attempting to
restart or reenergize
machines or equipment
that is locked or tagged
out.

28. EXERCISE
• What is hazardous
energy?
• List all Energy sources
Pnuematic Compressor

29. What is hazardous energy?
• Energy sources including
• electrical
• mechanical
• hydraulic
• pneumatic
• chemical
• thermal
• gravity
• radiation
• other sources in machines
and equipment
Some machines like this trim station
might have multiple sources of
energy.

30. 192
276
420
443
618
147(d)(4)(i)
147(c)(7)(i)
147(c)(6)(i)
147(c)(1)
147(c)(4)(i)
General Environment Controls
[1910.141 – .147]
30
LOCKOUT/TAGOUT – DEVELOPED
PROCEDURES
LOCKOUT/TAGOUT – PROGRAM
LOCKOUT/TAGOUT – PERIODIC INSPECTIONS
SUBPARTJ
LOCKOUT/TAGOUT – GENERAL
TRAINING
LOCKOUT/TAGOUT – SPECIFIC/ENFORCEMENT OF
PROCEDURES
Energy control procedures must be in writing including
specific procedures for each type of machine

31. Application of the Energy
Control Procedure
(in order)
1. Prepare for shutdown
2. Shut down equipment
3. Isolate all energy sources
4. Apply locks & tags
5. Release stored energy
6. Verify equipment isolation
7. Perform the task
8. Release from Lockout

32. Specific Procedure Example
• Shutdown the Mixer at the
button.
• Verify that all moving parts have
stopped.
• Lock and tag the knife switch with
appropriate lockout devices. (Be
sure to use your own personal
locks with only one key for each
lock, which you hold.)
• Verify that the mixer is locked out
by pushing on the ON button and
seeing that mixer blades do not
move. Worker locking out the mixer

33. Specific Procedures

34. Specific
Procedures
• Many are
pictures
orientation
so use for
lockout
procedures

35. Verification
• EACH energy source
must be verified to zero
energy state
• Capacitors?
Heal Sealer fatal in WI.
Capacitor discharge.

36. Verification
• Testing circuitry, cycling, visually inspecting position,
manually trying; monitoring movement or discharge;
observing bleeds, gauges, indicators, etc; or other
available means.
• Use technique(s) with the best degree of isolation
assurance.
• Do not rely on pressure gages alone to indicate
pressure. They are often inoperable.

37. Verification Citation $53,900

38. Verification 2015

39. Lockout Log
• A written procedure should be established with a log to track
locations, time, employees and devices.

40. Periodic Audits
• Done at least annually
• Conducted by an
authorized employee
• Must correct any
deficiencies
• Certified by employer
It's also important to test the e-stops, although this is
better done at the end of shift because it may be
difficult to get the automation running again.

41. Periodic Audits
• Machines where
procedures are used
• Date of inspection
• Employees included in
inspection
• Person who performed
inspection

42. Lockout Audits
• Audit lockout for new
people right away vs
waiting a year.

43. Sample Audit Results
• Lockout location info
not correct
• Contractor padlock not
identified to who it was
protecting
• PPE for lockout was not
correct for the hazard

44. Outside Contractors
• Must adhere to
standard’s
requirements
• Must inform each other
of respective program
responsibilities

45. •Worker died when shocked pulling out barrel fuse with pliers
•Electrical circuits must be locked out before doing any work on the
circuits if possible.
Fuse Pulling

46. Air Handlers
Worker touched an energized horizontal heating coil

47. Questions