Lototo
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Published by SALUSLockout/Tagout (LOTO) Safety Procedures =======================================
Date: 2025-09-04
Duration: \[DURATION] minutes
Presenter: \[PRESENTER NAME]
Location: \[LOCATION]
Objective
To understand and implement proper Lockout/Tagout procedures to prevent unexpected machine start-up or release of hazardous energy during maintenance and servicing.
Introduction
Lockout/Tagout (LOTO) is a critical safety procedure designed to protect employees from the dangers of hazardous energy release. This toolbox talk will cover the essential steps and precautions for effective LOTO implementation.
Key Points
- Importance of LOTO: LOTO procedures prevent accidental start-up of machinery or equipment during maintenance, protecting workers from serious injury or death.
- Authorized vs. Affected Employees: It's important to distinguish between authorized employees (those who perform LOTO) and affected employees (those who work in the area). Only authorized employees can perform lockout/tagout procedures.
- Energy Isolation: Identify all energy sources (electrical, mechanical, hydraulic, pneumatic, thermal, etc.) and ensure they are properly isolated before starting work.
- Verification: After applying locks and tags, verify that the equipment is indeed de-energized by attempting to start it up (following proper safety protocols).
Hazard Identification
- Unexpected machine start-up: Crushing injuries, amputations, electrocution.
- Release of stored energy: Burns, lacerations, fractures.
- Failure to properly identify energy sources: Exposure to hazardous energy, leading to injury or death.
Control Measures
- Develop and implement a written LOTO program.: The program should outline specific procedures for each piece of equipment.
- Identify all energy sources and isolating devices.: Clearly label all energy isolating devices (e.g., circuit breakers, valves).
- Use standardized lockout/tagout devices.: Locks and tags should be durable, standardized, and clearly identify the employee who applied them.
- Train all authorized and affected employees.: Training should cover the purpose and function of the LOTO program, as well as the specific procedures for each piece of equipment.
Personal Protective Equipment (PPE) Requirements
- Eye Protection: Always wear eye protection and personal safety equipment. [1]
- Gloves: Wear appropriate gloves to protect against electrical, thermal, or chemical hazards.
- Safety Boots: Wear safety boots to protect feet from impacts and punctures.
Real-World Example or Case Study
A maintenance worker was seriously injured when a conveyor belt started up unexpectedly during cleaning. The LOTO procedures were not followed, and the worker had not verified that the equipment was de-energized. This resulted in crushing injuries to the worker's arm.
Group Discussion
Discuss the following questions:
- What are some potential energy sources we might encounter in our work area?
- What steps can we take to improve our LOTO procedures?
- How do we ensure that all employees understand the LOTO procedures?
Emergency Procedures
- Immediately shut down the equipment if safe to do so.
- Evacuate the area if there is a risk of explosion or further energy release.
- Report the incident to a supervisor and initiate an investigation.
Questions and Answers
- Q: What do I do if I need to remove a lock that isn't mine?
A: Follow the established procedure for removing locks, which usually involves contacting a supervisor and verifying that it is safe to remove the lock.
- Q: What if I'm unsure about the energy sources?
A: Never proceed if you are unsure. Consult with a qualified person to identify and isolate all energy sources.
Summary
Recap of main points:
- LOTO is essential for preventing injuries during maintenance and servicing.
- Always follow the written LOTO procedures.
- Verify that the equipment is de-energized before starting work.
Action Items
Specific actions participants should take:
- Review the written LOTO program.
- Participate in LOTO training.
- Report any unsafe conditions or LOTO violations.
Report all hazards, near-misses, and incidents to your supervisor immediately.
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Sources used for this answer
[1] TEREX TH528C (manufactured after 9/14/2002) - Operator's Manual (PN 236499)
Page 19
Open source documentSource excerpt
# ! GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. All 2-3
[2] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 4/28/2003 to 12/17/2003) - Operator's Manual (PN 236501)
Page 19
Open source documentSource excerpt
# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operators cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. FIRST AID 2-3
[3] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 2/26/2004 to 7/15/2004) - Operator's Manual (PN 236503)
Page 19
Open source documentSource excerpt
# TABLE OF CONTENTS (cont.) # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. / 0 AII 2-3
[4] TEREX TH636C / TH644C / TH842C / TH844C (manufactured before 4/28/2003) - Operator's Manual (PN 236500)
Page 19
Open source documentSource excerpt
# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. - Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operators cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. 0 AII 2-3
[5] TEREX TH636C / TH644C / TH842C / TH844C (manufactured from 12/18/2003 to 2/25/2004) - Operator's Manual (PN 236502)
Page 19
Open source documentSource excerpt
# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. FIRST Allo 2-3
[6] TEREX TH644C / TH842C / TH844C (manufactured after 7/15/2004) - Operator's Manual (PN 236504)
Page 19
Open source documentSource excerpt
# SECTION 2 - GENERAL SAFETY (cont.) # GENERAL SAFETY # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats, goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. 2-3
[7] TEREX TH528C (manufactured before 2/14/2001) - Operator's Manual (PN 236497)
Page 7
Open source documentSource excerpt
# GENERAL SAFETY (cont.) ! GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operators cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow instructions provided with the first-aid kit and fire extinguisher. / FURST AID 1-3
[8] TEREX TH1048C / TH1056C - Operator's Manual (PN 236506)
Page 19
Open source documentSource excerpt
# TABLE OF CONTENTS (cont.) ! # GENERAL SAFETY ! # GENERAL SAFETY PROCEDURES ## SAFETY ALERT SYMBOL Stop and take time to read ALL safety alert messages. Follow all safety messages to avoid injury and/or death. ! ## WARNING ALWAYS wear eye protection and personal safety equipment. ## THE OPERATOR The operator must be fully trained and qualified to operate this machine. Before start-up or machine operation, the operator must learn the location and purpose of the: 1. Controls 2. Instruments 3. Indicator lights 4. Safety and instruction labels ## ACCIDENT PREVENTION Use protective clothing and safety equipment. Always use approved safety equipment such as: gloves, safety boots, safety hard hats/ goggles and ear protection when necessary. Wear protective clothing that is snug and belted where required. ## FIRE PREVENTION/FIRST AID Install a first-aid kit and fire extinguisher in the operator's cab. KEEP THE FIRST-AID KIT and FIRE EXTINGUISHER properly maintained. Follow the instructions provided with the first-aid kit and fire extinguisher. AII LEMIT 2-3
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