How can you create a lockout/tagout program that is both effective and efficient?

1 Assess your risks

The first step to creating a LOTO program is to identify and assess the hazards associated with each machine or equipment in your plant. You need to know the types, sources, and levels of energy involved, such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or gravitational. You also need to consider the potential consequences of an accidental start-up or release of energy, such as fire, explosion, shock, crush, cut, burn, or poisoning. Based on your risk assessment, you can prioritize the machines or equipment that require LOTO and determine the appropriate methods and devices to isolate and control the energy.

2 Develop your procedures

The next step is to develop written LOTO procedures for each machine or equipment that outlines the steps and responsibilities for performing LOTO. These procedures should include the purpose and scope of the LOTO, identification and verification of energy sources and isolation points, types and quantities of locks and tags needed, sequence of actions to isolate, lock, tag, and test energy sources, as well as instructions for restoring the energy sources and removing the locks and tags. To be effective, these procedures should be clear, concise, and consistent with relevant standards and regulations. It is also important to review and update them regularly to reflect any changes in the plant layout, equipment design, or operating conditions.

3 Train your workers

The third step is to provide training to your workers on the LOTO procedures and the hazards they are designed to prevent. Different levels of training should be conducted for different roles, such as authorized workers who perform LOTO, affected workers who operate or use the machines or equipment, and other workers who may encounter the LOTO devices. The topics covered in the training should include the purpose and importance of LOTO, recognizing and identifying energy sources and isolation points, using and applying locks and tags, complying with LOTO procedures and rules, communicating and coordinating with other workers involved in LOTO. This training must be done before any worker is assigned to a LOTO task and anytime there are changes in the procedures, equipment, or hazards. Additionally, it should be evaluated and reinforced periodically to guarantee that workers have sufficient knowledge and skills that are up-to-date.

4 Monitor your performance

The fourth step is to monitor and measure the effectiveness and efficiency of your LOTO program. You should have a system to track and record the LOTO activities, such as the frequency, duration, and incidents of LOTO. You should also have a system to audit and inspect the LOTO procedures, devices, and practices, such as the accuracy, completeness, and compliance of LOTO. Based on the data and feedback, you should identify and analyze the strengths and weaknesses of your LOTO program and implement corrective and preventive actions to improve it.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?