Lockout/tagout training helps save lives, prevent injuries

On average, lockout/tagout (LOTO) accidents kill 60 employees each year while seriously injuring over 3,000 more, according to Bureau of Labor Statistics (BLS) data. In addition to caught-in exposure, workers face struck-by, crushing, electric shock, burn, and other hazards when maintenance work is done without properly controlling the release of energy.

It’s not just maintenance workers who are exposed to these hazards. Any worker who operates or works around a machine can be exposed. In fact, many injuries happen when operators or other workers try to clear jams from process equipment without following safe LOTO procedures — in other words, when workers bypass machine guards to clear a jam without properly stopping the machine and controlling the hazardous energy the machine is capable of producing.

Training for authorized, affected, and other employees

All employees working in areas where energy-control procedures are used must be trained in their duties under LOTO. At minimum, training must cover:

• A review of the employer’s energy-control program,
• The elements of each energy-control procedure that relate to the employees’ duties, and
• The relevant requirements of the LOTO standard (29 CFR 1910.147).

The specific training an employee receives depends on whether that employee is an authorized employee, affected employee, or other employee.

Anyone doing machine service, maintenance, or repairs must be trained as an authorized employee. These employees apply their lock (or tag) to the equipment. Authorized employees must be trained:

• To recognize sources of hazardous energy;
• To understand the types and magnitudes of energy available to machinery and equipment and in the workplace;
• To know which LOTO devices are used with which energy-isolation devices;
• To locate the energy-isolating devices on each machine and piece of equipment;
• To use the proper sequence for applying LOTO devices to and removing them from the energy-isolating devices; and
• To only remove one’s personal LOTO devices from energy-isolation devices.

Affected employees use or operate equipment that can be locked or tagged out or work in an area where LOTO is used. These employees must be trained:

• On the purpose and use of energy-control procedures,
• To be alert and responsive to notifications about LOTO activities in their areas,
• To stay clear of machinery and equipment when notified that LOTO devices are going to be applied, and
• To position themselves a safe distance away when notified that LOTO devices have been removed.

If affected employees are assigned to do covered service or maintenance work, they become authorized employees and must be trained accordingly.

All other employees whose work operations are or may be in an area where LOTO procedures may be used need to be instructed about the procedures. They also must understand that they’re prohibited from attempting to restart or re-energize machines or equipment that are locked or tagged out.

Retraining employees

All authorized and affected employees must be retrained whenever there is:

• A change in their job assignments;
• A change in machines, equipment, or processes that present a new hazard; or
• A change in the energy-control procedures.

Additional retraining is required whenever an inspection reveals, or an employer reasonably suspects, that an employee fails to understand or comply with the steps of an energy-control procedure.