Il 1000 Keyence Manual

Control of Hazardous Energy
(Lockout / Tagout)
29 CFR 1910.147
February 2017
Training Agenda
• Purpose / Scope / Application
• Equipment Needed for a Successful LOTO
• Lockout Device Reminders
• Equipment Under Power
• tkSY, Inc. Energy Control Program Safe Operating Procedure (SOP)
• tkSY, Inc. Energy Control SOP: ADH 055
• Temporary Work Authorization Permit (ADH 124)
• Customer LOTO vs. tkSY, Inc. LOTO
• LOTO Inspections
• Reinforcement / Disciplinary Actions
• LOTO Summary
• Sample Scenarios
• Conclusion
• Quiz
thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

2 | February 2017 | Control of Hazardous Energy
NOTICE
For the purposes of this facility and course, ECPL is defined as
Energy Control Plan Layout also better known as Lockout Placard.

Purpose / Scope / Application
What Is “Control of Hazardous Energy”?
The purpose of lockout / tagout, is to block the flow of energy from a power source to the
equipment, in able to protect employees from injury due to unintended motion, start-up, or
release of stored energy whether it be thermal, mechanical, pneumatic, or electrical.
− The primary purpose of Lockout / Tagout is to prevent injuries.

− The energy of moving machinery can cause amputations, lacerations, fracture, and
even LOSS OF LIFE.
• OSHA mandates employers have the following available to all employees, contractors,
and commissioners:
− Written procedures and programs
− Training
− Inspections
− Hardware

Purpose / Scope / Application (continued)
The following 3 Levels of Employees Require LOTO Training:
Authorized – A person who locks out and tags out equipment. Training is required
and an annual inspection is performed by your tk supervisor, host, or contact.
Training covers the recognition of hazard sources, magnitude of energy available, and
methods used for control.
Affected – A person who uses a machine or equipment on which servicing or

maintenance is being performed under lockout / tagout. Training is required and an
annual inspection is performed by your tk supervisor, host, or contact. Training
covers the purpose and use of the energy control procedure.
Other – Employees, contractors, or commissioners whose work may be in an

affected area where LOTO procedures are present.

Authorized Employee Responsibilities Include:
• Ensuring and authorizing that all energy sources are locked out.
• Testing the equipment to verify residual energy is dissipated.
• Lockout / Tagout all equipment (may obtain assistance if necessary).
• Maintaining and servicing equipment, and/or troubleshooting.
• May work with engineers to troubleshoot equipment.
• Is trained to use LOTO.
• Completes task and verifies equipment is safe to start.
• Removes Personal lock(s) and tag(s) following LOTO.
• Completes start-up after LOTO.
• May coordinate multi-shift repair.
• Follow all safety rules required of LOTO / ADH 055 in RIMS.

Affected Employee Responsibilities Include:
• Operating equipment.
• May be required to occasionally adjust equipment that is subject to LOTO.
• MUST leave all LOTO devices in place.
• MUST verify equipment is safe during a LOTO activity.
• Follow all safety rules required of LOTO ADH 055 and ADH 023 in RIMS.

Other Employee Responsibilities Include:
• Taking part in an annual Safety Talk that covers the procedure and prohibition of any
attempts to restart or re-energize machines that are locked out & tagged out.
• Follow all safety rules required of LOTO ADH 055 and ADH 023 in RIMS.

thyssenkrupp System Engineering, Inc. must:
• Have a written program: See ADH 023 in RIMS.
• Review, maintain & revise written program.
• Ensure equipment is capable of de-energization.
• Provide appropriate levels of training & re-training.
• Ensure employee awareness.
• Remove locks per procedure.
• Complete lockout inspections and audits.
• Apply disciplinary actions.

LOTO is vital when:
• Employees, contractors, and/or commissioners are required to remove or bypass a safety
device such as a door switch, guards, or gates.
• Employees, contractors, and/or commissioners are required to place any part of their
body in harms way.
• Employees, contractors, and/or commissioners are exposed to any hazardous energy,
such as electrical, hydraulic, pneumatic, gravity, or another energy source. Customer sites
may also contain chemical, steam, and/or thermal energy.

Equipment Needed for a Successful Lockout / Tagout
• Locks
• Tags
• Blocks
• Chains
• Multi-lock hasps
• Wheel valve covers
• Ball valve covers

Equipment Needed for a Successful Lockout / Tagout (continued)
ALL Personal Locks Used at tkSY Are:

− Orange, MASTER brand safety locks
NO OTHER LOCKS ARE PERMITTED FOR USE ON EQUIPMENT.
− 1 lock and 1 tag per person. The key MUST be placed in your pocket or toolbox.
NO MASTER OR 2nd KEYS ARE ALLOWED.
− The employee, contractor, or commissioners name, date, and phone number MUST be printed on
the tag(s).
Department Locks Are:

− Blue, MASTER brand safety locks.
− A blue lock signals significant service is required, and that conditions may be hazardous and/or
restricted.
− Assembly Supervisors are the ONLY personnel permitted to use blue locks.

Equipment Needed for a Successful Lockout / Tagout (continued)
TAGS MUST:
• Indicate the identity (name, date, and phone number) of the employee, contractor, or
commissioner.
• Warning devices that are legible and understandable.
• Securely attached to locks.
• Print and format must be standardized.
• Capable of withstanding the workplace conditions.
tkSY, INC. USES:

− Red, White, and Black laminated tags.
− Printed header that reads “DANGER”.
− Personal info MUST be printed with a
permanent Sharpie or similar marker.

Lockout Device Reminders
• No employee, contractor, or fixed bid personnel can work under a blue

department lock.
• Orange and Blue locks CANNOT be manipulated.
• LOTO locks may NOT be used for any other purpose such as on lockers or
toolboxes.
• NEVER work under another’s lock or tag!
− Locks and Tags MUST be traceable to a single employee.
• Only the worker who placed the lock can remove it.
• E-stops and additional locks, tags, and hasps can
be checked out from the MSC machine so long
as you have a valid tkSY keycard assigned to you.
*If you have any major concerns, please take them to your tkSY supervisor or host IMMEDIATLEY. *

Equipment Under Power
Equipment under power means that there is

power to the panel disconnect.
Equipment under power MUST have

these 3 signs posted on the panel:
Warning, Live Voltage! ECPL ADH 055

tkSY, Inc. Energy Control Program Safe Operating Procedures (SOP)
FULL LOTO is REQUIRED AT ALL TIMES EXCEPT for the following specific
activities:
• During Set-up
• When tk authorized personnel are operating a Teach Pendant

DURING SET-UP:
Aligning, adjusting, and troubleshooting
− Machine is set to manual
− Robot controller servos are Locked out / Tagged out (if applicable)
− Portable e-stop button is connected to the guard door switch cable
− Warning sign shown below is posted temporarily near the door(s)

WHEN tkSY AUTHORIZED PERSONNEL ARE OPERATING THE TEACH PENDANT:
Only an Authorized Teach Pendant user (whose name is on the posted list):
− Is allowed inside of the machine.
− Has possession of the teach pendant at all times while inside of the machine.
*Please note that further evaluation is required for you to be authorized at tkSY to program robots*
Please contact your tk supervisor or host if you feel you should be evaluated.
THIS COURSE DOES NOT MAKE YOU A RECOGNIZED tk TEACH PENDANT USER!

Steps to Conduct Lockout / Tagout:
(1) Prepare for shutdown by:

-Notifying all affected workers of the upcoming disruption
-Evaluating potential hazards
(2) Perform a shutdown by:
-Utilizing normal stopping procedures (No E-stop or Interlock)
-Disabling all affected sources of energy according to the posted ECPL
(3) Isolate all energy sources on equipment
(4) Apply lockout devices and tags
(5) Release any stored energy
(6) Verify equipment isolation by:
-Making sure equipment is locked out
(7) Complete work task assignment

Steps to Release Lockout / Tagout:
(1) Inspect the area and equipment

-Notify all affected workers of the planned start-up
(2) Ensure all guards and guard doors are in place
(3) Restore system connections
(4) Remove locks and tags
(5) Restore equipment to power
(6) Conduct startup

Additional tkSY, Inc. LOTO Safe Operating Procedure Information:
• We have one SOP for lockout/tagout. =>ADH 055 which can be found in RIMS.
• Any deviations from the SOP will require tk supervisor, safety coordinator, and worker
signatures which signifies that they understand the risks and hazards associated with the
temporary work.
• Contract houses will provide 2 locks and 2 tags for contractors per the contract labor
supplier agreement.
• Audits and inspections will be held to ensure adherence to the bullet points stated above.

tkSY, Inc. Energy Control SOP: ADH 055
This document can be found

in our RIMS system by
searching “055” in the name
field.

Temporary Work Authorization Permit (ADH 124)
• LOTO special cases such as a magnet, laser, multiple robots, and/or multiple operators
and/or
• Any / all other conditions
REQUIRE a Temporary Work Authorization Permit (ADH 124 in RIMS)

Customer LOTO vs. tkSY, Inc. LOTO
Customer Lockout
Posted rules and expectations that are for tk field employees once the machines are
shipped and installed at any customer location.
tkSY, Inc. Lockout

Will be followed 100% at all times, by all persons, while in any tkSY, Inc. facility.
This applies to all customers, suppliers, visitors, contractors, employees and fixed bid
personnel.
***Lockout violations are cause for immediate dismissal.***
The tkSY, Inc. SOP ADH 055 applies to all employees, contractors, customers, suppliers and
any other visitor while in a tkSY, Inc. facility. ADH 055 will supersede any customer
procedures that may be posted temporarily on a machine while it is in a tkSY, Inc. facility
LOTO Inspections
Assembly Supervisors
− Inspect 5% or perform 10 inspections per year; whichever is greater.
− Reinforce training.
Safety Personnel
− Conduct audits by observation, verbal confirmation, or by lockout inspections.
They also may use other means to ensure training effectiveness and
understanding.
− Reinforce training.

Reinforcement / Disciplinary Actions
ADH 067 Energy Control Violation (which can be found in RIMS) is used ONLY for
LOTO violations. In short:
− This training course serves as the 1st verbal AND written warning should a
violation occur.
− Any offense may be disciplined accordingly up to and including termination of
employment for flagrant violation.
− Additional disciplinary actions include a 10-day suspension without pay.
− Re-training will be required for workers who have been suspended prior to their
work re-assignment. This is in order to ensure their full understanding and
cooperation with ADH 067.

LOTO Summary
• Follow the posted ADH 055 or Temporary Work Authorization Permit AT ALL
TIMES.
• Review the lock out postings.
• Refer to ADH 099 - Lock Removal policy (in RIMS) for the procedure on removing
abandoned locks.
• Communicate, Communicate, Communicate! Keep your co-workers informed
when Lockout / Tagout is in effect.
• Stay alert!
• Use common sense.
• Report any unsafe conditions or unsafe behaviors to your tk supervisor, contact,
or host IMMEDIATELY.

Scenarios
Let’s review a few scenarios to see what steps you should take in the event of a tk LOTO.

Scenario #1: Tool Alignment Verification
A cell has one robot which functions to move parts from one operating space to another
two times (3 spaces) in order to complete a process. The sequence of motion is as follows:
robot picks part, moves to operating space, releases, and returns to home position before
picking up the part again to move to the second operating space. The programmer notices
that the part is being misaligned in the working space and asks for the tooling to be
adjusted.
What steps should you take to make the adjustment?
First, notify all affected personnel in the work area.

Next, utilize normal stopping procedures to bring equipment to a neutral state or
home position.
Then, after identifying the problem in teach mode, you should lock out power to
the robot which is in home position, according to the ECPL.
Lastly, leave the part in the fixture, or mark the fixture, and make the adjustment.
Since the robot places the part into a stationary fixture, no power will be needed
to conduct the adjustment or to verify that the corrections are effective.

Scenario #2 : Fixture Adjustment
A similar station is in need of the same adjustment, except this station moves with the following
sequence: robot picks part, moves to operating space, robot motion stops in position and allows for
other work to be performed, and then moves onto next operating space. The robot does not return to
home position until after one part is complete and before the next begins.

Next, using teach mode and following the SOP, bring the robot to the working
position.
Then, after identifying the problem, lock out the servo motors of the robot in the
working position.
Lastly, make the adjustment, exit the cell, remove the lock, and attempt to verify
the corrections.
If the robot and working space are still incorrectly positioned; again lock out the
servo motors of the robot in the working position and repeat as necessary.
How is this different from the tool alignment verification?
Power is needed for this adjustment to be accurate. The robot does not return to
home position, and cutting power would enable the end effector from holding the
work piece.
Scenario #3A: Robot Adjustment (One Robot / One Adjustment)
A robot in a station has an end effector that needs an adjustment . The adjustment relies on
a pneumatic system and cannot be conducted accurately with a full lockout in place.

Then, verify that the Robot is in teach mode.
Lastly, as a tool maker or electrician you MUST have an E-STOP on your person AT
ALL TIMES for the duration of this adjustment. As a commissioner, you MUST use
the enabling device on the teach pendant AT ALL TIMES for the duration of this
adjustment.
Equal communication to complete this task SAFELY is required on both ends.

*THIS IS A HIGH RISK TASK THAT SHOULD NOT BE TAKEN LIGHTLY*

Scenario #3B: Robot Adjustment (Two Robots / One Adjustment)
There are two robots in a station and each has an end effector, but only one is in need of an
adjustment. The adjustment relies on a pneumatic system and cannot be conducted
accurately with a full lockout in place.

Then, verify that the robot is in teach mode.
Lastly, as a tool maker or electrician you MUST have an E-STOP on your person AT
ALL TIMES for the duration of this adjustment. As a commissioner, you MUST use
the enabling device on the teach pendant AT ALL TIMES for the duration of this
adjustment.
How does it differ from one robot / one adjustment ?
The second robot MUST BE COMPLETELY LOCKED OUT according to the ECPL. No
one is to be working on the second robot or any conveyor systems during the
adjustment period.

Scenario #4: Re-Tool
One of the stopping details on a fixture is chipped, and the integrity has been
compromised. In addition, it is misaligned with its contact point causing additional damage.
The stopping detail needs to be removed and taken to the machine shop to be “re-tooled”.
The station includes a conveyor system and a small robot. There are 4 electrical lockout
points including a main disconnect, two access gate interlocks, and a stand alone electrical
unit supplying power to the robot.
Then, verify that all energy sources have been locked out including the main
pneumatic drop and main electrical disconnect.
Lastly, because this system was identified to have a robot with a stand alone
power supply, an additional lock will be necessary in order to complete the
lockout.
Please Note
 A full lockout is REQUIRED to follow the ECPL, which is located on the main
disconnect panel.
 Also, a minimum of 4 locks will be required to complete this task for the duration
of the detail machining and installation process.
Scenario #5: Preventative Maintenance
You have been called upon by thyssenkrupp System Engineering to preform basic
preventative maintenance on our generator. You notice that the pump is incorrectly
functioning and in order to diagnose the problem you will need to attempt to run it.
What steps should you take to run the generator?
You should contact your tkSY supervisor, contact, or host IMMEDIATELY!
Regardless of the severity or how your company has identified best practice; ALL
unplanned maintenance activities require a specific pre-job line-up that is given
by your tkSY supervisor, contact, or host.

Lockout / Tagout Conclusion
This concludes the Lockout / Tagout Training slideshow.
Upon completion (with a score of 100%) of the following quiz, you will be considered
Lockout / Tagout authorized, and are expected to lockout tkSY equipment safely, according
to the rules and guidelines set forth in this training.
If you must retake the course, you can do so by visiting your Mindflash dashboard, and
clicking the “RETAKE” button.

Lockout / Tagout Conclusion
If you have any questions or concerns about our facility, please bring them to our attention
as soon as possible by emailing:
Training Support
ah.dg.training.support@thyssenkrupp.com
THANK YOU!


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Control of Hazardous Energy

• Purpose / Scope / Application

• Equipment Needed for a Successful LOTO

• Lockout Device Reminders

• Equipment Under Power

• tkSY, Inc. Energy Control Program Safe Operating Procedure (SOP)

• tkSY, Inc. Energy Control SOP: ADH 055

• Temporary Work Authorization Permit (ADH 124)

• Customer LOTO vs. tkSY, Inc. LOTO

• Reinforcement / Disciplinary Actions

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

− The primary purpose of Lockout / Tagout is to prevent injuries.

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

Affected – A person who uses a machine or equipment on which servicing or

Other – Employees, contractors, or commissioners whose work may be in an

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

ALL Personal Locks Used at tkSY Are:

Department Locks Are:

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

tkSY, INC. USES:

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

• No employee, contractor, or fixed bid personnel can work under a blue

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

Equipment under power means that there is

Equipment under power MUST have

Warning, Live Voltage! ECPL ADH 055

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

(1) Prepare for shutdown by:

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

(1) Inspect the area and equipment

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

This document can be found

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

tkSY, Inc. Lockout

***Lockout violations are cause for immediate dismissal.***

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

First, notify all affected personnel in the work area.

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

What steps should you take to make the adjustment?

First, notify all affected personnel in the work area.

Equal communication to complete this task SAFELY is required on both ends.

thyssenkrupp - Industrial Solutions - thyssenkrupp System Engineering

First, notify all affected personnel in the work area.

Lockout violations are cause for immediate dismissal.