Critical Steps to Creating an Effective Lockout Tagout Procedure
What are the critical steps required to create simple electronic versions of energy control procedures? (lockout tagout)
The first step is to review the job and identify the risks from various energy sources associated with performing the job.
Some typical examples of energy sources would include gravity (something that could fall while the job is being done), electricity (a disconnect that needs to be locked and tagged to keep someone from accidently energizing the machine while it is being worked on), pressurized air (a valve that needs to be locked to make sure that the device isn’t energized)(an air cylinder needs to be locked out and also have the potential energy removed to make sure that it cannot be released during performance of the job), you might also have steam pressure, water pressure, hydraulic pressure, to name a few.
Keeping track of all of your sources of energy in a table enables you to use them and then reuse them consistently as you create new lockout tagout procedures.
As you identify each step associated with creation of a procedure, always be sure and check out the OSHA example reference: OSHA CFR 1910.147 Appendix A, Typical minimal lockout procedures. You need to not only lockout each device, but you must also determine a method that validates that the energy has been removed from the device before someone begins work on the machine or device.
The old saying “a picture is worth a thousand words” really applies in this case, so take pictures of the actual apparatus to be locked to protect the worker. Recognizing a picture rather than hoping to match a number or written description to an item can really help prevent mistakes when it comes to using the procedure. It also helps to use color to emphasize exceptionally dangerous or complex energy devices for people to pay attention to when using the procedure.
If you don’t have a means of creating a procedure in a simple step by step manner using point and click and pull down menus, you should consider using a self-expanding, self-building database program. Another advantage of such a database program is that all of the procedure revisions can be managed and tracked within the system. Also, all audits can automatically notify employees when they are scheduled as well as employee training being tracked and validated. Furthermore, your maintenance program (CMMS computerized maintenance management system) can be connected via asset number or equipment number. Mechanics can count on this system to easily find a procedure when they are assigned work orders associated with these jobs. This will allow users to easily create compliance reports.
A good lockout tagout procedure can also tie closely to your Job Safety Analysis procedures and hopefully the safety tools you are using allow you to link these procedures together.
If you aren’t using a program that you say “This is so simple everyone should be using it,” or “this is so easy, what is the catch?”, then you should consider using BasicSafe lockout tagout software for your LOTO Program. Click the lock icon below to tour the BasicSafe lockout tagout module.
