Breaking Barriers: Overcoming Challenges in Lockout Tagout Compliance

In industries where heavy and hazardous machinery is operated, accidents are a common occurrence. However, such accidents can be prevented with the use of proper safety procedures and guidelines. Lockout Tagout is one such process that protects workers from hazardous energy release injuries during maintenance and repair procedures.

According to OSHA, “The Control of Hazardous Energy (Lockout Tagout) (29 CFR 1910.147) for general industry outlines measures for controlling different types of hazardous energy.” Lockout Tagout is the process of de-energizing and securing equipment, machinery, or processes to prevent dangerous energy from being reintroduced during maintenance or repair activities. Ever since its introduction by OSHA, it has been protecting workers from hazardous energy release and service work accidents.

Lockout Tagout compliance is not only necessary to ensure continued productivity but also to protect precious lives. In this article, we will discuss various challenges you might face while implementing LOTO, and strategies to effectively apply lockout tagout with a few real-life examples.

Understanding Lockout Tagout Compliance:

The United States Occupational Safety and Health Administration (OSHA) developed the regulation for the control of hazardous energy (Lockout/Tagout), Title 29 Code of Federal Regulations (CFR) Part 1910.147, in 1982 to help protect workers who routinely service workplace equipment.

Workers must be protected against the unexpected release of hazardous energy during repair work. This hazardous energy can be in the form of:

• Electrical (live wires, charged capacitors, energized circuits)
• Mechanical (moving parts like gears, blades, rollers; springs under tension)
• Hydraulic (high-pressure fluids)
• Pneumatic (compressed air, debris)
• Chemical (reactive chemicals, pressurized gas containers)
• Thermal (ovens, boilers, freezers)
• Gravitational energies (suspended overhead objects, heavy components) and many more.

As each industry has unique safety challenges and requirements, it is essential to implement LOTO solutions tailored to the specific needs of each sector.

Regulatory Compliance

The Lockout Tagout guidelines by OSHA detail the protocols and steps required to deactivate and de-energize machinery or equipment to avoid the release of hazardous energy.

ISO (International Organization for Standardization) 14118 "Safety of Machinery" and the US standard ANSI/ASSE Z244, are two other international standards that outline the use of "Zero Energy" (the no-voltage principle to avoid dangers when running devices). The ANSI/ASSP Z244.1 standard specifies guidelines for regulating hazardous energy using lockout/tagout procedures and alternate approaches.

Such standards assure safety on another level:

• Save lives by averting roughly 50,000 lockout tagout accidents and 120 fatalities every year.
• Reduce expenditures by minimizing labour time and insurance costs.
• Increase production by minimizing equipment downtime.

Common Challenges in LOTO Compliance:

Let’s discuss a few commonly faced challenges for Lockout Tagout and how you can effectively deal with them to ensure maximum safety.

Lack of Awareness and Training:

Inadequate Lockout Tagout training is one of the key reasons for LOTO failure. When authorized workers are not effectively trained on how to shut off, de-energize, and isolate hazardous energy sources, it leads to a lack of responsibility and careless application. At the same time, when affected employees are not trained on how to stay aware and be considerate of the ongoing process, they could unknowingly cause machine re-energization and put others in harm’s way.

To avoid any careless mistakes, every worker, especially authorized employees, must be trained to follow the written procedures. Giving in-person or interactive training to the right person will ensure that all procedures are being followed correctly, and it gives the authorized employee a sense of responsibility towards their safety. It is imperative to incorporate training and re-training in every safety protocol and update regularly.

Cultural Barriers:

Another critical challenge is the worker’s mindset. Workers often believe that lockout tagout is a time-consuming process and is not important. They fail to understand the hazards present even during routine maintenance and repair. In their rush to finish the day’s production and meet deadlines, they often don’t use LOTO devices or skip the written steps.

It is the employer’s duty to enforce the safety guidelines and develop a safety culture for all workers. When the employer demonstrates the need for effective and proper safety guidelines, the employee must follow all the rules and regulations. It creates a sense of safety and care for employee well-being, leading to a safety-first work culture.

Resource Constraints:

Often businesses think that Lockout Tagout is an expensive process.

Their budget constraints and other resource limitations lead companies to cut off excess expenses and prioritize their expenditures, which often results in safety protocols being overlooked.

In the long run, lockout tagout procedures save money, time, and lives. A proper lockout tagout process can be budget-friendly while being effective. High-risk areas require proper lockout tagout, but implementing LOTO is not an expensive task. Providing employees with adequate training and quality devices ensures a safety culture and more profits.

Technological Limitations:

Another reason for accidents, even when lockout tagout is applied, is technological limitations - rusted panels, outdated machinery, advanced energy control devices, and much more. Such equipment can cause re-energization even if a LOTO device is applied.

It is important to update and inspect your machinery and equipment for rust, broken panels, or any other limitations which might put a worker in harm’s way. Another method to ensure safety is to customize the LOTO device according to the machine’s specific requirement, whether through retrofitting or developing a new device especially for that equipment.

Strategic Approaches to Overcoming Challenges:

Comprehensive Training Programs:

Both personnel who may be impacted by the usage of these techniques and those who are authorized to perform LOTO procedures must receive training. An effective LOTO training program should include instruction on how to properly lock out or tag out equipment, as well as how to operate LOTO devices and other safety equipment. It should also include information about the dangers associated with the equipment being worked on, as well as precautions to avoid accidents and injuries.

Cultural Change Initiatives:

In a workplace, to make safety a priority, it needs to start at the top level. When managers, leaders, and employers show that they care about safety, workers understand its importance and follow in management’s footsteps. Also, rewarding safety through appreciation, awards, or certificates is highly motivating not only for the receiving employee but for his co-workers as well.

Investment in Safety Technology:

A safe workplace is a productive workplace. The employer must invest in employees' safety and well-being, whether it is through implementing procedures or providing the right LOTO devices. Specific LOTO devices like de-electric padlocks, cylinder locks, or quality valve covers help make the workplace safer and more productive.

Regular Audits and Continuous Improvement:

Regular audits help identify gaps in safety procedures through thorough inspections of machinery, equipment, and work processes to identify potential hazards. This ensures that all safety protocols are up-to-date and the plant is meeting the standards set by international bodies.

Case Studies and Success Stories:

#CASE 1 - During repairs on a pipeline carrying hot oil, employees followed proper lockout tagout procedures. After completion, all locks were removed, and the system was returned to its operating state. However, control-room personnel were unexpectedly instructed to start up the system five hours earlier than planned. Without knowledge of the early start-up, two supervisors decided to inspect the repairs themselves. They failed to implement any lockout/tagout procedures for the inspection and did not inform control-room personnel of their decision. When the system was started as instructed, oil flow resumed through the pipe, resulting in the fatalities of the two supervisors.

This case shows that all employees, not just those authorized to repair, must be notified about the maintenance process. Any personnel must attach his/her own lock before entering any hazardous areas.

#CASE 2 - A tragic incident occurred involving a 52-year-old welder who lost his life after being crushed by a hydraulic door on a metal shredder. The fatal accident happened as the employee was trying to clear a jammed piece of metal from the hydraulic door. Unfortunately, the object causing the obstruction fell away unexpectedly, causing the door to abruptly close on the worker. It was determined that the energy in the system had not been properly released, and the door had not been secured in an open position.

This case shows that even though it might have seemed like a minor task to remove the log, proper isolation procedures were required. If any task involves putting any part of the body in harm’s way, safety precautions must be used.

Conclusion

Lockout Tagout is not just for following compliance but to ensure worker safety and continued productivity. Protection from life-altering accidents like amputations, burns, broken bones, and losses can be avoided by taking calculative measures.

A LOTO process has both financial and ethical incentives when it is implemented properly and adheres to the standards set by OSHA. The above-mentioned accidents must inspire companies to have a 0-accident workplace with the right safety guidelines and procedures. When the company focuses on worker safety, it receives payback in the form of increased productivity, more profits, boosted morale, and a good brand reputation. Get in touch with us today at E-Square to empower your employees with the right tools and procedures needed to achieve ‘Zero Harm’ and address the complexities of your plant.