Common Lockout Tagout Mistakes Employees And Organisations Make

Lockout Tagout (LOTO) is a crucial safety procedure to prevent accidental machine start-ups and protect employees from hazardous energy sources during maintenance or repair work. This involves isolating a machine and placing locks and tags on the machine to keep it safely shut down and avoid any inadvertent startups.? Despite its importance, errors in lockout tagout procedures may lead to severe injuries or fatalities, making it essential to understand and address common LOTO mistakes.?

5 Common Lockout Tagout Mistakes Made by Employees?

Mistake #1: Skipping LOTO procedures for quick fixes?

A frequent error is bypassing LOTO for quick tasks like minor repairs to save time. For instance, a technician might bypass the process to fix a minor issue on a conveyor belt. This shortcut can be dangerous as machinery could restart unexpectedly, causing serious injuries. The risk is especially high in high-energy or high-speed machinery settings.?

Mistake #2: Improper use of locks and tags?

Misuse of locks and tags is another issue. Employees may leave keys in locks or use personal locks instead of designated lockout locks or isolation locks. Leaving keys in place risks unauthorised access, while using personal locks can create confusion about responsibility. Only authorised, clearly marked lockout locks must be used.?

Mistake #3: Failure to verify isolation?

Employees often fail to test machinery controls to confirm they are inoperative. For example, after locking out a machine, an employee might neglect to verify isolation, which may lead to dangerous situations if the machine restarts. Incidents where workers were injured due to improper verification highlight the importance of this step.?

Mistake #4: Dependence on others??

Relying on colleagues to perform your lockout tasks is risky. For instance, an employee asks a coworker to lockout a machine while they work elsewhere. This practice can lead to miscommunication and a lack of accountability. It’s crucial for each employee to handle their own procedures to ensure safety.?

Mistake #5: Ignoring multiple lockout procedures?

Ignoring lockout procedures when multiple employees are involved can be hazardous. In multi-step maintenance several workers need to maintain different parts of a machine, each must follow proper procedures to control all energy sources. Failure to do so can lead to accidents, as seen when shared machinery was re-energised because not all workers adhered to LOTO steps.?

7 Common Lockout Tagout Mistakes Made by Organisations?

Mistake #1: Incomplete or missing procedures?

Organisations sometimes fail to develop comprehensive, equipment-specific lockout guidelines. Generic or outdated procedures can create safety gaps, increasing accident risks. Procedures should be detailed, tailored to each piece of equipment, and regularly reviewed.?

Mistake #2: Failure to conduct regular inspections?

Neglecting regular LOTO inspections can lead to outdated or non-compliant practices. Periodic inspections are vital for identifying and addressing issues before they result in accidents, ensuring procedures remain effective.?

Mistake #3: Inadequate employee training?

Insufficient or outdated training undermines LOTO effectiveness. Organisations need current, comprehensive training programs that cover all aspects of LOTO and address any new equipment or procedures. Strong training fosters a safety-conscious culture.?

Mistake #4: Poor communication?

Effective communication is crucial for success. Poor communication during repair, service or maintenance can cause confusion and unsafe practices. Clear, consistent messaging about requirements and process changes helps ensure all employees adhere to safety protocols.?

Mistake #5: Failure to identify all energy sources?

Overlooking hidden or secondary energy sources is a serious mistake. Failing to identify and isolate all potential energy sources can result in accidents. Examples include injuries from not addressing secondary sources like hydraulic or pneumatic systems.?

Mistake #6: Unauthorised removal of locks or tags?

Unauthorised removal of locks or tags can lead to unintended machine start-ups and accidents. Organisations should implement strict procedures for removing locks and tags, ensuring that only authorised personnel perform this task under controlled conditions.?

Mistake #7: Using cheap or generic lockout devices?

To keep things economical or to cut costs, organisations often choose generic devices that do not meet specific industry standards or regulations, which can lead to legal issues during inspections.?

Sticking to Lockout Tagout procedures is vital for protecting workers and maintaining a safe work environment. Both employees and organisations must be vigilant in avoiding common lockout tagout mistakes. Employees should diligently follow these LOTO procedures and seek proper training, while organisations need to ensure comprehensive procedures, regular inspections, and effective communication. Prioritising lockout compliance prevents accidents and creates a culture of safety.?