Factories and other industrial facilities are rife with safety hazards that can lead to all sorts of workplace injuries, from mild to fatal injuries. Many of these accidents are caused by non-compliance with lockout tagout procedures. Lockout tagout refers to a set of procedures or a system that can help ensure workplace safety and minimize the number of workplace injuries. It ensures that potentially dangerous machines and equipment are completely and properly shut off before maintenance work begins.
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The Occupational Safety and Health Administration (OSHA) established the Lockout Tagout Standard (.147) for the control of hazardous energy. To follow this standard, an employee has to take the necessary steps to prevent a machine or piece of equipment from turning back on while under maintenance. This involves isolating the power source and, more importantly, implementing a proper lockout tagout procedure for an extra level of security.
The process prevents other employees from turning on and operating the machine when it’s unsafe to do so. A lockout tagout station can be instrumental in helping employees maintain a proper and compliant lockout tagout program, effectively keeping the workplace safe.
Any facility that has to comply with the OSHA Lockout Tagout Standard (.147) will benefit from the use of a lockout tagout station. A lockout station provides a designated area to store and organize LOTO devices, making them easily accessible and ensuring that safety protocols are followed consistently. As such, it should be able to accommodate all manner of lockout tagout devices, such as padlocks, keys, inspection tags, and hasps.
It’s best if this station is easily visible and strategically placed in an easily accessible spot. However, it’s also important to make sure that this station can be locked and secured. This will prevent improper use by unauthorized personnel, as well as the accidental loss or damage of any of the devices.
Lockout tagout stations come in various designs to meet the diverse needs of different industries and workplaces. Understanding the types available can help you choose the most suitable one for your specific requirements.
Type of Station Description Advantages Best For Wall Mounted Lockout Tagout Station Fixed installations on walls or vertical surfaces Easy access, organized storage, high visibility Fixed workstations, limited workspace Portable Lockout Tagout Station Compact and lightweight, designed for mobility Flexibility, convenience, compact storage Mobile tasks, large facilities Lockout Tagout Station Cabinet Larger units with multiple shelves and compartments Ample storage, secure, durable High-volume needs, secure environmentsA typical lockout tagout (LOTO) station contains several essential components designed to isolate and secure hazardous energy sources during maintenance and servicing. Here are the primary components found in a LOTO station:
A lockout tagout program will not only help with compliance but will also help prevent workplace injuries and fatalities. In fact, a formal lockout tagout program is an OSHA requirement.
Employees will also have to be properly trained to be able to execute the program. With the help of a lockout tagout station, employees will find it easier to stick to established routines which will make them less likely to deviate from the steps of the program. This will ultimately prevent employees from operating machines that are under maintenance, keeping maintenance employees safe from any accidental release of energy.
The goals of a good lockout tagout program are simple, but it will likely involve many steps and procedures to achieve these goals. A lockout tagout station will be able to help employees follow these steps to the letter with minimal confusion.
Think of a lockout tagout station as something akin to a key holder. A key holder is where members of a household hang all their keys at the end of the day to make sure that they can always be found in one place. Organizing keys can prevent loss and can help maintain efficient routines. A lockout tagout station works in much the same way.
Lockout tagout devices are the tools that physically prevent the accidental release of energy and the accidental operation of machines under maintenance. They are not easily replaceable; there are OSHA guidelines that specify the kind of devices that should be used in lockout tagout procedures.
Therefore, if a padlock gets lost or damaged, for example, it cannot be replaced by just any run-of-the-mill padlock from the hardware store. The same goes for other devices, such as lockout hasps and LOTO tags. Because these devices are vital to keeping the workplace safe, they should also be stored in a secure place. Any damage or loss can be disruptive to routines, can delay important maintenance work, and can also be dangerous for maintenance employees.
Having an organized storage spot for lockout tagout devices can also help employees work with the same machines without confusion. This can minimize and even prevent mistakes that can be harmful to maintenance workers.
Additionally, lockout tagout programs need to be machine-specific. This means that if a facility has a variety of machines, it cannot have just one lockout tagout program that encompasses all those machines. Each machine must have its own lockout tagout program, and the employees who work with and on that machine have to be well-trained in executing that specific program.
Having a lockout tagout station in strategic spots or in close proximity to a machine will help maintain machine-specific programs. It eliminates confusion, helps enforce routines, and helps employees remember their training better.
Typically, a lockout tagout station is wall-mounted for easy and secure access. Because of the nature of a lockout tagout station and its functions, it’s best to install it in a strategic spot.
One option is to put the lockout tagout station somewhere central, in a spot that’s easily accessible to everyone who needs it. This placement is ideal if the station stores devices that can be used on multiple machines. Another option is to place the station right next to a machine, preferably in close proximity to the machine’s power source. This placement is best if the devices in that station are used for that specific machine only.
Below are key maintenance tasks and best practices for using LOTO stations effectively:
Lockout tagout stations don’t have to cost a lot of money to be effective and durable. A good lockout tagout station can set you back about $100 at least, but it won’t cost you more than $300, this varies greatly depending on the size and range of products the station comes with. At these prices, you’ll get a set of various lockout tagout devices as well as a durable and lockable case for security and storage.
Both a station and a kit can function and be used separately. A lockout tagout station provides a static and reliable place to store standard devices. A lockout tagout kit, meanwhile, is simply a collection of different lockout tagout devices that serve different functions.
However, the devices in a kit can also replace the devices that are usually found in lockout stations. In case any device is lost, damaged, or otherwise unusable, the devices in a lockout tagout kit can take its place.
Because OSHA guidelines also regulate the devices used in lockout tagout procedures, device replacements can’t just come from anywhere. Fortunately, having a kit on standby can help provide immediate solutions to any loss or damage.
Emerging trends in lockout tagout technology include the integration of digital and IoT systems, which provide automated tracking, real-time monitoring, and remote control of LOTO procedures. These advancements enhance compliance, efficiency, and safety by ensuring accurate documentation and immediate updates.
Additionally, innovations in LOTO stations, such as modular and customizable designs, improve storage and organization, making it easier to manage lockout devices. Advanced training tools, including virtual reality simulations, are also being developed to provide more effective and engaging LOTO training.
Lockout tagout stations should be placed in easily accessible areas near high-risk equipment or where maintenance work frequently occurs to ensure quick access to LOTO devices.
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The purpose of a lockout station is to provide a centralized and organized location for storing lockout tagout devices, ensuring they are readily available and properly managed to enhance workplace safety and compliance.
Lockout tagout stations must comply with OSHA standards, be durable, provide adequate storage for all necessary devices, include clear labeling, and be placed in accessible locations to ensure effective lockout tagout procedures.
LOTO should be used whenever servicing or maintenance is being performed on machinery or equipment to prevent accidental energy release and protect workers from hazards.
The tools for LOTO include padlocks, lockout tags, lockout hasps, valve lockouts, circuit breaker lockouts, plug lockouts, and any other device necessary to isolate and secure energy sources.
When it comes to the possibility of someone accidentally restarting a piece of equipment that another employee is working on, the only device that is protecting the employee is their lockout lock. It’s imperative that employees understand how to properly use their locks and also know to never lend out their lock or key, to ensure exclusive control at all times. When employees understand safety, and how to use keyed or combination locks properly, you can achieve a successful lockout/tagout program.
A major requirement of OSHA’s Control of Hazardous Energy regulation (.147), is the use of protective materials and hardware during lockout.
OSHA requires that all locks must be:
In addition:
The employer must decide whether these locks are individually assigned or available from a pool of locks within their facility. It is also important to note that if an isolation point does not accept a lock, a lockout device with a lock must be used in this situation to keep the disconnect in the off position.
Keeping in mind all these requirements and recommendations, let’s determine whether to use combination, keyed, or both types of locks.
Keyed locks are the main type of lock used under OSHA’s .147. Keyed locks are also the cheapest and safest option when it comes to lockout/tagout. It’s important to know that if your lock comes with two keys, the best practice is to dispose of the second key.
Combination locks are another option that is acceptable under OSHA’s .147, but there are additional safety measures that should be taken for their safe use. Just like keyed locks, only one person should be able to open the lock, which means only one person may know the combination to that lock. Therefore, it is not recommended to use combination locks for shared locks since the combination would have to get passed from employee to employee.
One benefit of using combination locks is that you don’t have to worry about losing the key for the lock, but instead must remember a series of numbers to open the lock. Since many maintenance employees already have a ring of keys, the use of combination locks will help to reduce the number of keys that they must carry around.
One major drawback with the use of combination locks is that nobody else is permitted to know the combination, not even a manager. If it’s believed that the employees will be able to remember the combination, and keep it to themselves only, then a site could consider combination locks.
If a site intends to have a pool of shared locks, such as a peg board of locks available, keyed locks will be the only option.
Per OSHA, multiple-keyed or keyed-alike locks may not be used for the purpose of lockout/tagout. Any locks used must have only a single key, which must be under the exclusive control of the employee that applies the lock and is performing the service.
The subject of multiple-keyed or master-keyed locks used for lockout/tagout can be a confusing subject when referencing OSHA’s .147. The standard requires that the lockout device be under the exclusive control of the employee applying the locks and performing the maintenance. In a letter of interpretation, OSHA states that a duplicate or master key may not exist for the purpose of removing a lock with a lost or misplaced key. In fact, any lock determined to have a missing key must not be used and should be immediately removed and replaced.
For more information regarding multi-keyed lockout locks, please refer to the letter of interpretation provided by the Federal OSHA.
If someone’s lock needs to be removed, the authorized employee who installed it should be the one to remove it. When this isn’t possible, a forced lock removal form and proper procedure should be followed.
According to OSHA’s lockout/tagout regulation, “When the authorized employee who applied the lockout or tagout device is not available to remove it, that device may be removed under the direction of the employer, provided that specific procedures and training for such removal have been developed, documented, and incorporated into the employer’s energy control program.”
In other words, under proper authorization of the employer, a supervisor may remove an employee’s lockout lock. This exception is only allowed under the circumstances that:
1. The employee who placed the lock is unavailable and,
2. It is necessary that the unit be returned to normal operation.
When faced with this situation, follow these simple steps to confirm it is properly handled.
DO:
DON'T:
Employers must have a proper lockout/tagout program in place and a policy regarding the removal of lockout devices with steps that should be followed. After proper steps have been taken to remove the lockout device, standard protocol for re-energization of the equipment must be performed.
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