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LO/TO

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Toolbox Talk: Lockout/Tagout (LO/TO)

Date: [DATE] Duration: [DURATION] minutes Presenter: [PRESENTER NAME] Location: [LOCATION]

Objective

The objective of this toolbox talk is to ensure that all employees understand the importance of Lockout/Tagout (LO/TO) procedures to control hazardous energy during maintenance and servicing of machinery. By the end of this session, participants should be able to identify potential energy hazards and apply LO/TO procedures effectively.

Introduction

Lockout/Tagout (LO/TO) is a critical safety procedure used to ensure that machines are properly shut off and not able to be started up again prior to the completion of maintenance or repair work. This procedure is essential to prevent accidental machine start-up and the release of stored energy, which can lead to serious injuries or fatalities.

Presenter Note: Engage the audience by asking if anyone has personal experience related to LO/TO.

Key Points

  • Understanding Hazardous Energy: Hazardous energy includes electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources in machines and equipment [1].
  • Importance of LO/TO: Proper LO/TO procedures prevent unexpected energization or release of stored energy, which could cause injury [2].
  • Group LO/TO Procedures: When multiple employees are involved, each must affix their personal lock to a group lockbox to ensure safety [3].
  • Verification of Isolation: Before starting work, verify that the machine is de-energized and isolated from energy sources [4].
  • Shift Changes: Procedures must ensure continuity of LO/TO protection during shift changes to minimize exposure to hazards [5].

Hazard Identification

Common hazards related to LO/TO include:

  • Unexpected Energization: Can lead to severe injuries if machines start unexpectedly.
  • Stored Energy Release: Residual energy in systems can cause harm if not properly controlled.
  • Inadequate LO/TO Procedures: Failure to follow procedures can result in accidents.

Presenter Note: Encourage participants to share any additional hazards they've encountered.

Control Measures

Discuss the hierarchy of controls:

  • Elimination: Remove the need for energy during maintenance if possible.
  • Engineering Controls: Use lockboxes and lockout devices to secure energy sources [6].
  • Administrative Controls: Implement and enforce LO/TO procedures and training [2].
  • PPE: Use appropriate personal protective equipment as a last line of defense.

Safe Work Procedures

  1. Notify all affected employees of the LO/TO procedure [7].
  2. Shut down the machine using the normal stopping procedure [7].
  3. Isolate the machine from its energy source(s) [7].
  4. Apply lockout or tagout devices to energy isolating devices [8].
  5. Verify that the machine is de-energized before starting work [4].

Presenter Note: If possible, demonstrate the safe work procedure or use visual aids.

Personal Protective Equipment (PPE) Requirements

  • Safety Glasses: Use when working near potential energy sources.
  • Gloves: Wear appropriate gloves to protect against electrical or mechanical hazards.
  • Hard Hats: Use in areas where there is a risk of falling objects.

Emphasize the importance of proper PPE use and maintenance.

Real-World Example or Case Study

Discuss a scenario where failure to follow LO/TO procedures resulted in an accident. Highlight what went wrong and the lessons learned.

Presenter Note: Ask participants if they can relate this example to their own experiences.

Group Discussion

Discuss the following questions:

  1. What are the potential consequences of not following LO/TO procedures?
  2. How can we improve our current LO/TO practices?
  3. What challenges have you faced when implementing LO/TO?

Presenter Note: Encourage active participation and facilitate the discussion.

Emergency Procedures

Outline the steps to take in case of an emergency related to LO/TO:

  1. Stop all work immediately.
  2. Notify a supervisor or safety officer.
  3. Ensure the area is safe and secure.
  4. Follow the company's emergency response plan.

Questions and Answers

Encourage participants to ask questions and provide answers to common questions related to LO/TO.

  • Q: What should you do if you find a machine without a lockout device?

A: Report it immediately and do not attempt to use the machine.

  • Q: Can tagout be used instead of lockout?

A: Only if the energy isolating devices are not lockable and additional safety measures are in place [2].

Summary

Recap the main points covered in the toolbox talk:

  • Importance of LO/TO in preventing accidents.
  • Key steps in the LO/TO procedure.
  • The role of PPE in LO/TO safety.
  • The need for continuous verification and communication.

Action Items

List specific actions participants should take following this toolbox talk:

  1. Review and understand the LO/TO procedures for your work area.
  2. Ensure all personal locks and tags are available and in good condition.
  3. Report any issues or concerns with LO/TO procedures to your supervisor.

Remember: Safety is everyone's responsibility. Always follow LO/TO procedures to protect yourself and your coworkers.

Report all hazards, near-misses, and incidents to your supervisor immediately.

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8 source record(s)

Sources used for this answer

[1] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1819

Open source document

Source excerpt

Oregon Occupational Safety and Health Division Oregon Administrative Rules AO 2-2017 Division 2 - (D) Each authorized employee must affix a personal lockout or tagout device to the group lockout device, group lockbox, or comparable mechanism when he or she begins work and must remove those devices when he or she stops working on the machine or equipment being serviced or maintained. - (c) Procedures must be used during shift or personnel changes to ensure the continuity of lockout or tagout protection, including provision for the orderly transfer of lockout or tagout device protection between off-going and oncoming employees, to minimize their exposure to hazards from the unexpected energizing or start-up of the machine or equipment or from the release of stored energy. - (d) Whenever outside servicing personnel are to be engaged in activities covered in [redacted phone], the on-site employer and the outside employer must inform each other of their respective lockout or tagout procedures, and each employer must ensure that his or her personnel understand and comply with restrictions and prohibitions of the energy control procedures being used. - (e) If energy isolating devices are installed in a central location and are under the exclusive control of a system operator, the following requirements apply: - (A) The employer must use a procedure that affords employees a level of protection equivalent to that provided by the implementation of a personal lockout or tagout device. - (B) The system operator must place and remove lockout and tagout devices in place of the authorized employee under paragraphs (4), (6)(d), and (7)(d) of this rule. - (C) Provisions must be made to identify the authorized employee who is responsible for (that is, being protected by) the lockout or tagout device, to transfer responsibility for lockout and tagout devices, and to ensure that an authorized employee requesting removal or transfer of a lockout or tagout device is the one responsib

[2] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1642

Open source document

Source excerpt

Oregon Occupational Safety and Health Division Division 2 - (1) The machine or equipment has no potential for stored or residual energy or reaccumulation of stored energy after shut down which could endanger employees; - (2) the machine or equipment has a single energy source which can be readily identified and isolated; - (3) the isolation and locking out of that energy source will completely deenergize and deactivate the machine or equipment; - (4) the machine or equipment is isolated from that energy source and locked out during servicing or maintenance; - (5) a single lockout device will achieve a locked-out condition; - (6) the lockout device is under the exclusive control of the authorized employee performing the servicing or maintenance; - (7) the servicing or maintenance does not create hazards for other employees; and - (8) the employer, in utilizing this exception, has had no accidents involving the unexpected activation or re-energization of the machine or equipment during servicing or maintenance. - A. If a written procedure is required but not available, the employees will not start work until a lockout permit is completed and approved. - B. The department where the work is to be performed is responsible for assigning a Lockout Overseer to verify compliance with the permit procedure requirements. - C. One person, thoroughly knowledgeable with the equipment and the hazardous energies involved will be designated as the Responsible Person. - D. The Lockout Overseer will accompany the Responsible Person while completing the permit requirements. - E. Each personal lock shall be labeled identifying the worker. - F. The completed permit will be available at the job site or at the group lockout device while employees are working on the equipment. - V. Additional Requirements for Group Lockout - A. The Responsible Person will place the first 'secondary lock' on the lockbox.

[3] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 979

Open source document

Source excerpt

J Division 2 AO 1-2025 Oregon Administrative Rules Oregon Occupational Safety and Health Division ## Sequence Of Lockout - (1) Notify all affected employees that servicing or maintenance is required on a machine or equipment and that the machine or equipment must be shut down and locked out to perform the servicing or maintenance. ## Name(s)/Job Title(s) of affected employees and how to notify. - (2) The authorized employee shall refer to the company procedure to identify the type and magnitude of the energy that the machine or equipment utilizes, shall understand the hazards of the energy, and shall know the methods to control the energy. ## Type(s) and magnitude(s) of energy, its hazards and the methods to control the energy. - (3) If the machine or equipment is operating, shut it down by the normal stopping procedure (depress stop button, open switch, close valve, etc.). ## Type(s) and location(s) of machine or equipment operating controls. - (4) Deactivate the energy isolating device(s) so that the machine or equipment is isolated from the energy source(s). ## Type(s) and location(s) of energy isolating devices. - (5) Lockout the energy isolating device(s) with assigned individual lock(s). - (6) Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems, and air, gas, steam, or water pressure, etc.) must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc.

[4] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1638

Open source document

Source excerpt

Oregon Occupational Safety and Health Division - (4) Examples of Procedures for Group Lockout/Tagout. Examples are presented for the various methods of lockout/tagout using lockbox procedures. An example of an applicable method for complex process equipment is also presented. The following procedures address circumstances ranging from a small group of servicing/maintenance employees during a one-shift operation to a comprehensive operation involving many workers over a longer period. - (a) Type A. Each authorized employee places his/her personal lock upon each energy isolating device and removes it upon departure from that assignment. Each authorized employee verifies or observes the deenergization of the equipment. - (b) Type B. Under a lockbox procedure, a lock is placed upon each energy isolation device after de-energization. The key(s) are then placed into a lockbox. Each authorized employee assigned to the job then affixes his/her personal lock to the lockbox. As a member of a group, each assigned authorized employee verifies that all hazardous energy has been rendered safe. The lockout/tagout devices cannot be removed or the energy isolating device turned on until the appropriate key is matched to its lock. - (c) Type C. After each energy isolating device is locked/tagged out and the keys placed into a master lockbox, each servicing/maintenance group 'principal' authorized employee places his/her personal lock upon the master lockbox. Then each principal authorized employee inserts his/her key into a satellite lockbox to which each authorized employee in that specific group affixes his/her personal lock. As a member of a group, each assigned authorized employee verifies that all hazardous energy has been rendered safe. Only after the servicing/maintenance functions of the specific subgroup have been concluded and the personal locks of the respective employees have been removed from the satellite lockbox can the principal authorized employee remove his/her l

[5] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 978

Open source document

Source excerpt

Oregon Occupational Safety and Health Division Oregon Administrative Rules AO 1-2025 Division 2 Note: The following Appendix to 1910.147 serves as a nonmandatory guideline to assist employers and employees in complying with the requirements of this section, as well as to provide other helpful information. Nothing in the Appendix adds to or detracts from any of the requirements of this section. ## Appendix A to 1910.147 Typical Minimal Lockout Procedure - ## General The following simple lockout procedure is provided to assist employers in developing their procedures so they meet the requirements of this standard. When the energy isolating devices are not lockable, tagout may be used, provided the employer complies with the provisions of the standard which require additional training and more rigorous periodic inspections. When tagout is used and the energy isolating devices are lockable, the employer must provide full employee protection (see paragraph (c)(3)) and additional training and more rigorous periodic inspections are required. For more complex systems, more comprehensive procedures may need to be developed, documented and utilized. ## Lockout Procedure Lockout procedure for (Name of Company for single procedure or identification of equipment if multiple procedures are used.) ## Purpose This procedure establishes the minimum requirements for the lockout of energy isolating devices whenever maintenance or servicing is done on machines or equipment. It shall be used to ensure that the machine or equipment is stopped, isolated from all potentially hazardous energy sources and locked out before employees perform any servicing or maintenance where the unexpected energization or start-up of the machine or equipment or release of stored energy could cause injury. ## Compliance With This Program All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout. The authorized employees are r

[6] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1636

Open source document

Source excerpt

Oregon Occupational Safety and Health Division ## Appendix A (Non-Mandatory) - (1) Group Lockout/Tagout. The group lockout/tagout procedures described in the Pulp and Paper standard require each authorized employee to be in control of potentially hazardous energy release during their servicing/maintenance work assignments. Under most circumstances, where servicing/maintenance is to be conducted during only one shift by an individual or a small number of persons working together, the installation of each individual's lockout/tagout device upon each energy isolating device would not be a burdensome procedure. However, when many energy sources or many persons are involved, and/or the procedure is to extend over more than one shift, (possibly several days, or weeks) consideration must be given to the implementation of a lockout/tagout procedure that will ensure the safety of the employees involved and will provide for each individual's control of the energy hazards. The following procedures are presented as examples to illustrate the implementation of a group lockout/tagout procedure involving many energy isolating devices and/or many servicing/maintenance personnel. They illustrate several alternatives for having authorized employees affix personal lockout/tagout devices in a group lockout/tagout setting. These examples are not intended to represent the only acceptable procedures for conducting group operations. - (2) Definitions. Various terms used in the examples are defined below. - (a) Primary Authorized Employee is the authorized employee who exercises overall responsibility for adherence to the company lockout/tagout procedure. (See 1910.147 (f)(3)(ii)(A).) - (b) Principal Authorized Employee is an authorized employee who oversees or leads a group of servicing/maintenance workers (e.g., plumbers, carpenters, electricians, metal workers, mechanics). - (c) Job-Lock is a device used to ensure the continuity of energy isolation during a multi- shift operation. It

[7] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1817

Open source document

Source excerpt

Oregon Occupational Safety and Health Division Oregon Administrative Rules AO 2-2017 Division 2 - (e) Following the application of lockout or tagout devices to energy isolating devices, all potentially hazardous stored or residual energy must be relieved, disconnected, restrained, or otherwise rendered safe. - (f) If there is a possibility of reaccumulation of stored energy to a hazardous level, verification of isolation must be continued until the servicing or maintenance is completed or until the possibility of such accumulation no longer exists. - (g) Before starting work on machines or equipment that have been locked out or tagged out, the authorized employee must verify that isolation and deenergizing of the machine or equipment have been accomplished. If normally energized parts will be exposed to contact by an employee while the machine or equipment is deenergized, a test must be performed to ensure that these parts are deenergized. - (7) Release from lockout/tagout. Before lockout or tagout devices are removed and energy is restored to the machine or equipment, procedures must be followed and actions taken by the authorized employees to ensure the following: - (a) The work area must be inspected to ensure that nonessential items have been removed and that machine or equipment components are operationally intact. - (b) The work area must be checked to ensure that all employees have been safely positioned or removed. - (c) After lockout or tagout devices have been removed and before a machine or equipment is started, affected employees must be notified that the lockout or tagout devices have been removed. - (d) Each lockout or tagout device must be removed from each energy isolating device by the authorized employee who applied the lockout or tagout device. However, if that employee is not available to remove it, the device may be removed under the direction of the employer, provided that specific procedures and training for such removal have been develope

[8] Rules for the Administration of the Oregon Safe Employment Act (General Occupational Safety and Health, Division 2, OSHA Oregon)

Page 1816

Open source document

Source excerpt

Division 2 AO 2-2017 Oregon Administrative Rules Oregon Occupational Safety and Health Division - (5) Notification. Affected employees must be notified by the employer or authorized employee of the application and removal of lockout or tagout devices. Notification must be given before the controls are applied and after they are removed from the machine or equipment. Note to paragraph (5): See also paragraph (7) of this rule, which requires that the second notification take place before the machine or equipment is reenergized. - (6) Lockout/tagout application. The established procedures for the application of energy control (the lockout or tagout procedures) must include the following elements and actions, and these procedures must be performed in the following sequence: - (a) Before an authorized or affected employee turns off a machine or equipment, the authorized employee must have knowledge of the type and magnitude of the energy, the hazards of the energy to be controlled, and the method or means to control the energy. - (b) The machine or equipment must be turned off or shut down using the procedures established for the machine or equipment. An orderly shutdown must be used to avoid any additional or increased hazards to employees as a result of the equipment stoppage. - (c) All energy isolating devices that are needed to control the energy to the machine or equipment must be physically located and operated in such a manner as to isolate the machine or equipment from energy sources. - (d) Lockout or tagout devices must be affixed to each energy isolating device by authorized employees. - (A) Lockout devices must be attached in a manner that will hold the energy isolating devices in a "safe" or "off" position. - (B) Tagout devices must be affixed in such a manner as will clearly indicate that the operation or movement of energy isolating devices from the "safe" or "off" position is prohibited. - (i) Where tagout devices are used with energy isolating devic

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