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CONTROL OF HAZARDOUS ENERGY

Snamprogetti SAFETY TRAINING

LOCKOUT/TAGOUT- SLIDE 1 OF 67
COURSE ATTENDEES
 Facility Engineers
 Process Engineers
 Safety Committees
 Machine Operators
 Corporate Managers
 Equipment Operators
 Department Managers
 First Line Supervisors
 Maintenance Departments
 Accident Investigation Team Members

LOCKOUT/TAGOUT- SLIDE 2 OF 67
COURSE OBJECTIVES
 Teach The Student to Recognize Where
Lockout/Tag-out Is Needed.
 Allow the Student to Develop an Understanding of
the the Local Lockout/Tag-out Policy.
 Introduce Techniques Needed to Select the
Appropriate Lockout/Tag-out Devices.
 Teach the Student to Successfully Conduct
Lockout/Tag-out Operations.
 Introduce the Rules for Safe Lockout/Tag-out.

LOCKOUT/TAGOUT- SLIDE 3 OF 67
STUDENT LEARNING OUTCOMES

 Recognize Where Lockout/Tag-out Is Needed.


 Understand the Local Lockout/Tag-out Policy.
 Select the Appropriate Lockout/Tag-out Devices.
 Successfully Conduct Lockout/Tag-out Operations.
 Introduce the Rules for Safe Lockout/Tag-out.

LOCKOUT/TAGOUT- SLIDE 4 OF 67
REGULATORY STANDARD
THE GENERAL DUTY CLAUSE

EMPLOYERS MUST: Furnish a place of employment


free of recognized hazards that are causing or are likely
to cause death or serious physical harm to employees.

LOCKOUT/TAGOUT- SLIDE 5 OF 67
REGULATORY STANDARD
CONTROL OF HAZARDOUS ENERGY

- Safety and Health Standards

- General Industry

- Lockout Tag-out Standard

LOCKOUT/TAGOUT- SLIDE 6 OF 67
CIRCUMSTANCES OF INJURY

HOW MOST INJURIES OCCUR


IN ORDER OF OCCURRENCE
 Injured by Moving Machinery Part.
 Made Contact With Energized Part.
 Injured by Physical Hazard (Heat, Chemicals).
 Injured by Falling Machine Part.



LOCKOUT/TAGOUT- SLIDE 7 OF 67
CIRCUMSTANCES OF INJURY

ACTIVITY AT TIME OF ACCIDENT


FREQUENCY OF OCCURRENCE
1. Un-jamming Object(S) From Equipment
2. Cleaning Equipment
3. Repairing Equipment
4. Performing Routine Maintenance
5. Installing Equipment

LOCKOUT/TAGOUT- SLIDE 8 OF 67
CIRCUMSTANCES OF INJURY
ACTIVITY AT TIME OF ACCIDENT
FREQUENCY OF OCCURRENCE

6. Adjusting Equipment
7. Doing Set-up Work
8. Performing Electrical Work
9. Inspecting Equipment
10. Testing Materials

LOCKOUT/TAGOUT- SLIDE 9 OF 67
CIRCUMSTANCES OF INJURY
REASONS FOR EQUIPMENT NOT BEING TURNED OFF
 Afraid of Slow Down in Production.
ON OFF
 Afraid It Would Take Too Long.
 Not Required by Company Procedure.
 Worker Didn't Know Power Was on.
SYSTEM
 Worker Didn't Know How to Turn Off. CONTROL
 Did Not Think It Was Necessary. SWITCH
 Task Could Not Be Done With Power Off.

LOCKOUT/TAGOUT- SLIDE 10 OF 67
CIRCUMSTANCES OF INJURY
REASONS FOR EQUIPMENT BEING TURNED ON

 Accidentally Turned on by Injured Employee


 Co-Worker Accidentally Turned Equipment On
 Equipment Moved When Jam-up Cleared
ON OFF
 Equipment Unexpectedly "Cycled"
 Parts Still in Motion (Coasting)

SYSTEM
CONTROL
SWITCH

LOCKOUT/TAGOUT- SLIDE 11 OF 67
CASE STUDY #1
KILLED BY THE MOVING PARTS OF A SAW

Narrative: An Employee Was Cleaning the Unguarded Side of


an Operating Granite Saw. The Employee Was
Caught in the Moving Parts Of The Saw and
Pulled Into a Nip Point Between The Saw Blade
and the Idler Wheel, Resulting In Fatal Injuries.

Citation: Failure to Shutdown or Turn off Equipment To


Perform Maintenance.

LOCKOUT/TAGOUT- SLIDE 12 OF 67
CASE STUDY #2
DECAPITATED BY SHEARING MACHINE

Narrative: An Employee Was Removing Scrap From Beneath


a Large Shear When a Fellow Employee Hit the
Control Button Activating The Blade. The Blade
Cycled and Decapitated The Employee Cleaning
Scrap.

Citation: Failure to Shutdown or Turn off Equipment To


Perform Maintenance.

LOCKOUT/TAGOUT- SLIDE 13 OF 67
CASE STUDY #3
KILLED BY PNEUMATIC DOOR

Narrative: An Employee Was Partially Inside of an Asphalt


Mixing Machine Changing Its Paddles. Another
Employee, While Dusting in The Control Room,
Accidentally Hit a Toggle Switch Which Caused
the Door of the Mixer to Close, Striking the First
Employee on the Head and Killing Him.

Citation: Failure to Isolate Equipment From Energy Sources


Before Attempting Any Repair, Maintenance or
Servicing.

LOCKOUT/TAGOUT- SLIDE 14 OF 67
DEFINITION OF EMPLOYEES

 Authorized Employee
The Person Who Locks or Tags Out Machines To
Perform Servicing or Maintenance.

 Affected Employee
An Employee Whose Job Requires Him or Her To
Operate or Use a Machine or Piece of Equipment
On Which Servicing or Maintenance Is Being
Performed.

LOCKOUT/TAGOUT- SLIDE 15 OF 67
DEFINITION OF EMPLOYEES

 Designated Inspector
 Does Not Utilize the Specific Procedure.
 The Person Who Inspects the LO/TO Procedure.
 Is an Authorized Employee.

LOCKOUT/TAGOUT- SLIDE 16 OF 67
TRAINING REQUIREMENTS

 Authorized Employee
 Recognition of Hazardous Energy Sources.
 Type and Magnitude Energy Sources.
 Energy Isolation and Control Methods.

LOCKOUT/TAGOUT- SLIDE 17 OF 67
TRAINING REQUIREMENTS

 Affected Employee
 Purpose and Use of The Energy Control Program.

LOCKOUT/TAGOUT- SLIDE 18 OF 67
TRAINING REQUIREMENTS

 All Other Employees


 Procedures and Prohibitions Relating To Attempts to
Restart or Reenergize Machines or Equipment Which Are
Locked Out or Tagged Out..

LOCKOUT/TAGOUT- SLIDE 19 OF 67
RETRAINING REQUIREMENTS

Authorized and Affected Employees


Retraining Provided When There Is a:
 Change in Job Assignment.
 Change in Machines, Equipment or Processes.
 Change in Energy Control Procedures.
 Close-Call Event.
 Failure in the Procedures.
 Reason to Doubt Employee Proficiency.

LOCKOUT/TAGOUT- SLIDE 20 OF 67
ENERGY CONTROL PROGRAM

 THREE ELEMENTS TO THE PROGRAM:

1. ENERGY CONTROL PROCEDURES

2. EMPLOYEE TRAINING

3. PERIODIC INSPECTIONS

LOCKOUT/TAGOUT- SLIDE 21 OF 67
DEFINITION OF LOCKOUT

Lockout Is Defined as:


The Placement of a Lockout Device on an Energy Isolating
Device, in Accordance With an Established Procedure,
Ensuring That the Energy Isolating Device and the Equipment
Being Controlled Cannot Be Operated Until the Lockout
Device Is Removed.

LOCKOUT/TAGOUT- SLIDE 22 OF 67
DEFINITION OF ENERGY ISOLATING DEVICE

 Block
 Line Valve
 Disconnecting Switch
 Manually Operated Switch
 Any Other Device That Isolates Energy

LOCKOUT/TAGOUT- SLIDE 23 OF 67
TYPES OF ENERGY SOURCES
 HYDRAULIC
 PNEUMATIC
 MECHANICAL
 RADIOACTIVE
 THERMAL DANGER

 ELECTRICAL HIGH
VOLTAGE

 CHEMICAL

LOCKOUT/TAGOUT- SLIDE 24 OF 67
TYPES OF ENERGY STATES

ACTIVE ENERGY STORED ENERGY

110 VOLTS AC HOT SURFACE

LOCKOUT/TAGOUT- SLIDE 25 OF 67
TYPES OF ENERGY STATES

ACTIVE ENERGY
 VOLTAGES
 EXTERNAL PRESSURIZED LINE FEEDS
TO THE MACHINE

LOCKOUT/TAGOUT- SLIDE 26 OF 67
TYPES OF ENERGY STATES

STORED ENERGY
 INTERNAL LINE PRESSURES
 CAPACITORS
 SURFACE TEMPERATURES
 MECHANICAL TENSION (SPRINGS, ETC.)
 COASTING OF PARTS
 CHEMICAL (OPPOSING pH)
 GRAVITY

LOCKOUT/TAGOUT- SLIDE 27 OF 67
THE SCOPE OF LOCKOUT/TAGOUT

AREAS
 SERVICING OF MACHINES AND EQUIPMENT
 MAINTENANCE OF MACHINES AND EQUIPMENT

AREAS NOT REGULATED:


 CONSTRUCTION, AGRICULTURE AND MARITIME
 WORK CONTROLLED BY ELECTRIC UTILITIES
 ELECTRIC UTILITY INSTALLATIONS
 OIL AND GAS WELL DRILLING AND SERVICING

LOCKOUT/TAGOUT- SLIDE 28 OF 67
ACTIVITIES COVERED

 NORMAL OPERATIONS:
1. Covered If an Employee Must Remove or Bypass Guards or
Devices

2. Covered Where Employees Are Required to Put A Body Part in


a Machine Process Area

3. Covered Where Employees Are Required to Put A Body Part in


a Machine Having a Danger Zone

LOCKOUT/TAGOUT- SLIDE 29 OF 67
TAGOUT REQUIREMENTS

DANGER
LOCKED
OUT
DO NOT OPERATE
This Lock/Tag may
only be removed by

NAME: _______________
DEPT : _______________
EXPECTED COMPLETION
DATE: ________________
TIME: _________________

LOCKOUT/TAGOUT- SLIDE 30 OF 67
REQUIREMENTS IF TAGOUT IS USED

 SOME KEY POINTS ABOUT TAGS:


DANGER
 Tags Are Only Warning Devices! LOCKED
 Tags Must Be Securely Attached! OUT
DO NOT OPERATE

 May Evoke False Sense of Security! This Lock/Tag may


only be removed by


NAME: _______________
Tags Do Not Provide Physical Restraint! DEPT : _______________
EXPECTED COMPLETION


DATE: ________________
Tags Must Never Be Defeated or Ignored! TIME: _________________

 Must Withstand Environmental Conditions!


 Tags Must Be Legible and Understandable!
 Tags Are Only Removed by the Responsible Person.

LOCKOUT/TAGOUT- SLIDE 31 OF 67
LOCK OUT SEQUENCE OF EVENTS
1. Preparation for Shutdown
2. Shutdown
3. Machine or Equipment Isolation
DANGER
4. Application of Lockout/Tag-out Devices LOCKED
5. Testing of LO/TO OUT
DO NOT OPERATE
6. Servicing or Maintenance This Lock/Tag may
only be removed by
7. Removal of LO/TO Devices NAME: _______________
DEPT : _______________
8. Re-Energize EXPECTED COMPLETION
DATE: ________________
TIME: _________________
9. Equipment Reactivation

LOCKOUT/TAGOUT- SLIDE 32 OF 67
WRITTEN PROGRAM REQUIREMENTS

ALL CONTRACTORS MUST: WRITTEN PROGRAM


---------- ----------
---------- ----------
---------- ----------
---------- ----------
----------

----------
Maintain a Written Program. ----------
---------- ----------
----------

 Review the Program on an Annual Basis.


 Develop Detailed Energy Control Procedures.
 Review Individual LO/TO Procedures Annually.
 Make the Written Program Available to All Affected
Employees During Each Work Shift.

LOCKOUT/TAGOUT- SLIDE 33 OF 67
ENERGY CONTROL PROCEDURES

STANDARD REQUIRES THAT:


Procedures Be Developed, Documented and
Utilized for Control of Potentially Hazardous Energy
When Employees Are Engaged in the Activities
Covered by the Standard.

LOCKOUT/TAGOUT- SLIDE 34 OF 67
PROGRAM MANAGEMENT FORMS

COMMONLY USED PROGRAM MANAGEMENT FORMS

 Decision Flow Chart.


 Lockout Tag-out Equipment Assessment.
 Equipment Procedural Review.
 Machine/Equipment Listing.
 Non-Routine Task - (Protective Measures)

LOCKOUT/TAGOUT- SLIDE 35 OF 67
PROGRAM MANAGEMENT FORMS

COMMONLY USED PROGRAM MANAGEMENT FORMS:

 DECISION FLOW CHART:


Used to Provide a Standardized Decision Making Process for
Establishment and Maintenance of the Energy Control Program.

 LOCKOUT TAGOUT EQUIPMENT ASSESSMENT FORM:


Used to Gather Information From Specific Equipment From the
Shop Floor. The Information Gathered Can Then Be Used to
Develop Specific Energy Control Procedures for Individual
Equipment.

LOCKOUT/TAGOUT- SLIDE 36 OF 67
PROGRAM MANAGEMENT FORMS

COMMONLY USED PROGRAM MANAGEMENT FORMS


 EQUIPMENT PROCEDURAL REVIEW FORM:
Equipment Having Energy Control Procedures Must Have the
Procedures Reviewed on an Annual Basis. The Procedural
Review Form Is Used to Track Annual Review Dates.

 MACHINE/EQUIPMENT LISTING FORM:


Used to Identify Specific Equipment and Machinery That Have
Been Assessed and Are Considered Part Of the Energy Control
Program.

LOCKOUT/TAGOUT- SLIDE 37 OF 67
PROGRAM MANAGEMENT FORMS

COMMONLY USED PROGRAM MANAGEMENT FORMS

 NON-ROUTINE TASK - (PROTECTIVE MEASURES) FORM:


Used by Supervisors to Assess Jobs That Are Not Performed on
a Routine Basis, but Where the Possibility of Injury to an
Employee Exists.

LOCKOUT/TAGOUT- SLIDE 38 OF 67
ENERGY CONTROL PROCEDURES
PROCEDURES MUST CONTAIN:
1. Statement of Intended Use.
2. Steps for Shut-Down and Energy Control.
3. Steps for LO/TO Device Placement, Transfer and Removal.
4. Determination of Responsibility.
5. Steps for Testing LO/TO.
LO/TO
CHECK
LIST

LOCKOUT/TAGOUT- SLIDE 39 OF 67
EXCEPTIONS TO THE REQUIREMENT
TO HAVE WRITTEN LOTO PROCEDURES
ALL OF THE FOLLOWING EIGHT CONDITIONS MUST EXIST:

1. No Potential for Residual, Stored or Re-accumulation of Energy.

2. Contains Only One Energy Source Which Is Readily Identified


and Isolated.

3. Isolating & Locking Out Results in Complete De-Energization.

4. The Machine or Equipment Is Isolated or Locked Out During


Maintenance.

5. One Lockout Device Will Achieve Complete Lockout.

LOCKOUT/TAGOUT- SLIDE 40 OF 67
EXCEPTIONS TO THE REQUIREMENT
TO HAVE WRITTEN LOTO PROCEDURES
ALL OF THE FOLLOWING EIGHT CONDITIONS MUST EXIST:

6. The Lockout Device Is Under Exclusive Control Of An


Authorized Employee

7. Servicing/Maintenance Does Not Produce Hazards For Other


Employees

8. No Previous Energy Control Accident History Exists for the


Employer

LOCKOUT/TAGOUT- SLIDE 41 OF 67
ENERGY CONTROL PROCEDURES

 PROCEDURES INSPECTED ANNUALLY

 INSPECTIONS PERFORMED BY -
“AUTHORIZED EMPLOYEES” OTHER THAN PRIMARY

 LOCKOUT REVIEWED BETWEEN -


INSPECTOR AND AUTHORIZED EMPLOYEES

 TAGOUT REVIEWED BETWEEN -


INSPECTOR AND AUTHORIZED/AFFECTED EMPLOYEES

LOCKOUT/TAGOUT- SLIDE 42 OF 67
ENERGY CONTROL PROCEDURES

ANNUAL INSPECTIONS MUST INCLUDE:

 DATE OF INSPECTION

 IDENTIFICATION OF MACHINE OR EQUIPMENT

 EMPLOYEES INCLUDED IN INSPECTION

 PERSON PERFORMING INSPECTION

LOCKOUT/TAGOUT- SLIDE 43 OF 67
RELEASE FROM LOCKOUT/TAGOUT

THE AUTHORIZED EMPLOYEE MUST:

1. INSPECT WORK AREA FOR HAZARDS


2. CLEAR ALL EMPLOYEES
3. NOTIFY ALL AFFECTED EMPLOYEES
4. REMOVE ENERGY ISOLATING DEVICES

LOCKOUT/TAGOUT- SLIDE 44 OF 67
IMPORTANT POINTS TO REMEMBER
 WHERE LOCKOUT CAN BE USED:

IT MUST BE*

 WHERE LOCKOUT CANNOT BE USED:

TAGOUT PROCEDURES MUST BE INITIATED

*(Unless It Can Be Demonstrated That Full Protection Can


Be Achieved by Other Means)

LOCKOUT/TAGOUT- SLIDE 45 OF 67
GROUP LOCKOUT/TAGOUT

 FOUR SPECIFIC REQUIREMENTS


1. Responsibility Vested in a Single Authorized Employee.
2. The Authorized Employee Must Have the Authority To
Determine Exposure Status of Group Members.
3. With Multiple Crews the Authorized Employee Must Be
Assigned the Responsibility of The Overall Job.
4. The Authorized Employee Shall Affix an Individual LO/TO
Device at the Beginning of Work and Remove It at
Completion of the Work.

LOCKOUT/TAGOUT- SLIDE 46 OF 67
GROUP LOCKOUT/TAGOUT

WHEN THE AUTHORIZED EMPLOYEE IS UNAVAILABLE

 PROCEDURES MUST INCLUDE, AS A MINIMUM:


1. Proof That the Employee Who Applied the Device Is
Unavailable.
2. A Valid Attempt to Inform the Employee Who Applied the
Device, That It Has Been Removed.
3. Adequate Notice to the Employee Who Applied The Device,
of the Removal of the Device Before That Employee
Returns to Work.

LOCKOUT/TAGOUT- SLIDE 47 OF 67
CONTRACTOR SAFETY REQUIREMENTS

OUTSIDE CONTRACTORS MUST:

 Inform Representatives of the Facility Of Their LO/TO


Procedures and Devices.
COMPANY REPRESENTATIVES MUST:

 Inform the Contractor of Internal LO/TO Procedures


and Devices.
 Ensure That the Contractor(S) Are Following LOTO
Procedures.

LOCKOUT/TAGOUT- SLIDE 48 OF 67
TIPS FOR USING CONTRACTORS

 Remember, You Control Your Facility!


 Review Their Procedures With Them Before Starting
the Job!
 Determine Their Safety Performance Record!
 Determine Who Is in Charge of Their People!
 Determine How They Will Affect Your Employees!
 Ensure Your Data on Your Facility Is Accurate!

LOCKOUT/TAGOUT- SLIDE 49 OF 67
KEY ELEMENTS TO AN EFFECTIVE PROGRAM

1. Develop and Strictly Adhere to LO/TO Procedures.


2. Establish and Enforce Safe Work Practices.
3. Ensure Proper Training and Supervision.
4. Strengthen and Modify Present Policies.
5. Understand the Relationship Between 29 CFR 1910.147 And
the Business or Industry Involved.

LOCKOUT/TAGOUT- SLIDE 50 OF 67
EQUIPMENT REQUIREMENTS
DEVICES AND TAGS MUST BE:
1. Durable
2. Standardized
3. Identifiable
4. Substantial

DEVICES AND TAGS ARE:


1. Designed to Prevent Accidental Energization.
2. Not Designed As a Substitution for Security.

LOCKOUT/TAGOUT- SLIDE 51 OF 67
CASE STUDIES IN LOCKOUT TAGOUT

CASE STUDY # 1: WORKER KILLED BY MIXING MACHINE


CASE STUDY # 2: WORKER KILLED BY HIGH VOLTAGE
CASE STUDY # 3: WORKER KILLED BY STORAGE MECHANISM
CASE STUDY # 4: WORKER KILLED BY PARTS UNLOADER
CASE STUDY # 5: DECAPITATED BY SHEARING MACHINE
CASE STUDY # 6: KILLED BY PNEUMATIC DOOR

LOCKOUT/TAGOUT- SLIDE 52 OF 67
CASE STUDY #1
WORKER KILLED BY MIXING MACHINE

NARRATIVE: An employee was assigned the task of cleaning the


inside of a sand mixer. The task was conducted
during a break in the production cycle, caused by
routine maintenance work. He did this without
anyone else’s knowledge. While he was engaged
in this, out of sight and hearing of the others, an
electrician started the machine, killing the man
inside. This plant had a written lockout procedure,
training had been given, and all affected employees
(including the deceased), were issued keys and
locks.

LOCKOUT/TAGOUT- SLIDE 53 OF 67
QUESTIONS TO BE CONSIDERED

 What caused the death of the worker?


DANGER
 Do you believe there are multiple causes?
LOCKED
 Are multiple OSHA Standard violations involved? OUT
DO NOT OPERATE
 What could upper management have done? This Lock/Tag may
only be removed by

 What could the supervisor have done? NAME: _______________


DEPT : _______________
EXPECTED COMPLETION


DATE: ________________

What could the co-workers have done? TIME: _________________

 To what extent was attitude responsible?


 To what extent is a lack of written policy responsible?
 To what extent is a lack of training responsible?
 Do you believe there is a single cause to this accident that,
if removed would have prevented it?

LOCKOUT/TAGOUT- SLIDE 54 OF 67
CASE STUDY #2
WORKER KILLED BY HIGH VOLTAGE

NARRATIVE: A 13,800-volt main circuit breaker was under


routine inspection. A test instrument was used to
check for electrical energy. No electrical energy
was detected at the primary power contacts in the
circuit breaker. To verify the operation of the
tester, the sensitivity was readjusted and checked
against a known 120-volt receptacle. The tester
was found to be operable. As the journeyman
electrician approached one of the contacts with a
shop towel, an explosion, engulfed him in flames.
The power from the public utility company to the
main circuit breaker had not been shut off.

LOCKOUT/TAGOUT- SLIDE 55 OF 67
QUESTIONS TO BE CONSIDERED

 What caused the death of the worker?


 Do you believe there are multiple causes? DANGER
LOCKED
 Are multiple OSHA Standard violations involved? OUT

DO NOT OPERATE
What could upper management have done? This Lock/Tag may
only be removed by

 What could the supervisor have done? NAME: _______________


DEPT : _______________
EXPECTED COMPLETION

 What could the co-workers have done? DATE: ________________


TIME: _________________

 To what extent was attitude responsible?


 To what extent is a lack of written policy responsible?
 To what extent is a lack of training responsible?
 Do you believe there is a single cause to this accident that,
if removed would have prevented it?

LOCKOUT/TAGOUT- SLIDE 56 OF 67
CASE STUDY #3
WORKER KILLED BY STORAGE MECHANISM

NARRATIVE: A stock handler entered a computer controlled


storage and retrieval area apparently to perform
stock inventory. While performing this work he
was crushed between the robot retrieval vehicle
and a third level post, when the vehicle responded
to an electronic command. It was found that even
though there were a number of disconnect
switches on the vehicle and main console none
had been used. The plant had no written lockout
procedure and workers had not been trained or
advised regarding entry into this area.

LOCKOUT/TAGOUT- SLIDE 57 OF 67
QUESTIONS TO BE CONSIDERED

 What caused the death of the worker?


DANGER
 Do you believe there are multiple causes?
LOCKED
 Are multiple OSHA Standard violations involved? OUT
DO NOT OPERATE
 What could upper management have done? This Lock/Tag may
only be removed by

 What could the supervisor have done? NAME: _______________


DEPT : _______________
EXPECTED COMPLETION


DATE: ________________
What could the co-workers have done? TIME: _________________

 To what extent was attitude responsible?


 To what extent is a lack of written policy responsible?
 To what extent is a lack of training responsible?
 Do you believe there is a single cause to this accident that,
if removed would have prevented it?

LOCKOUT/TAGOUT- SLIDE 58 OF 67
CASE STUDY #4
WORKER KILLED BY PARTS UNLOADER

NARRATIVE: The part presence switch to an unloading fixture


was sticking on an automatic transfer line. The
jobsetter removed a guard and was standing at the
side of the line to observe the operation of the
switch. He apparently leaned forward just as the
unloader actuated; it caught his right side and
crushed him between the moving unloader and the
support post for the guard. The company had a
written lockout program and the employee had
attended operator awareness training for control of
hazardous energy.

LOCKOUT/TAGOUT- SLIDE 59 OF 67
QUESTIONS TO BE CONSIDERED

 What caused the death of the worker?


 Do you believe there are multiple causes? DANGER
LOCKED
 Are multiple OSHA Standard violations involved? OUT

DO NOT OPERATE
What could upper management have done? This Lock/Tag may
only be removed by

 What could the supervisor have done? NAME: _______________


DEPT : _______________
EXPECTED COMPLETION

 What could the co-workers have done? DATE: ________________


TIME: _________________

 To what extent was attitude responsible?


 To what extent is a lack of written policy responsible?
 To what extent is a lack of training responsible?
 Do you believe there is a single cause to this accident that,
if removed would have prevented it?

LOCKOUT/TAGOUT- SLIDE 60 OF 67
CASE STUDY #5
DECAPITATED BY SHEARING MACHINE

NARRATIVE: An employee was removing scrap from beneath a


large shear when a fellow employee hit the control
button activating The blade. The blade cycled and
decapitated the employee cleaning scrap. The
company had no written lockout procedure and
workers had not been trained or advised regarding
the hazards associated with machinery.

LOCKOUT/TAGOUT- SLIDE 61 OF 67
QUESTIONS TO BE CONSIDERED
 What caused the death of the worker?
 Do you believe there are multiple causes? DANGER
LOCKED
 Are multiple OSHA Standard violations involved? OUT
 What could upper management have done? DO NOT OPERATE
This Lock/Tag may
only be removed by

 What could the supervisor have done? NAME: _______________


DEPT : _______________
EXPECTED COMPLETION

 What could the co-workers have done? DATE: ________________


TIME: _________________

 To what extent was attitude responsible?


 To what extent is a lack of written policy responsible?
 To what extent is a lack of training responsible?
 Do you believe there is a single cause to this accident that,
if removed would have prevented it?

LOCKOUT/TAGOUT- SLIDE 62 OF 67
CASE STUDY #6
KILLED BY PNEUMATIC DOOR

NARRATIVE: A maintenance employee was partially inside of an


asphalt mixing machine changing its paddles.
Another employee, while dusting in the control
room, accidentally hit a toggle switch which
caused the door of the mixer to close, striking the
first employee on the head and killing him. The
company had a written lockout program and the
maintenance had attended training for control of
hazardous energy.

LOCKOUT/TAGOUT- SLIDE 63 OF 67
QUESTIONS TO BE CONSIDERED
 What caused the death of the worker?
 Do you believe there are multiple causes? DANGER
LOCKED
 Are multiple OSHA Standard violations involved? OUT
 What could upper management have done? DO NOT OPERATE
This Lock/Tag may


only be removed by

What could the supervisor have done? NAME: _______________


DEPT : _______________


EXPECTED COMPLETION
What could the co-workers have done? DATE: ________________
TIME: _________________

 To what extent was attitude responsible?


 To what extent is a lack of written policy responsible?
 To what extent is a lack of training responsible?
 Do you believe there is a single cause to this accident that,
if removed would have prevented it?

LOCKOUT/TAGOUT- SLIDE 64 OF 67
ENERGY CONTROL PROGRAM
REVIEW

 THREE ELEMENTS OF THE PROGRAM:


1. ENERGY CONTROL PROCEDURES

2. EMPLOYEE TRAINING

3. PERIODIC INSPECTIONS

LOCKOUT/TAGOUT- SLIDE 65 OF 67
OSHA'S PERCEPTION
OF A SUCCESSFUL PROGRAM

1. Detailed Energy Control Procedures


2. Extensive Employee Training Programs
3. Periodic Reinforcement of Training
4. Sufficient Discipline Regarding Implementation

LOCKOUT/TAGOUT- SLIDE 66 OF 67
WORK AT WORKING SAFELY
Key to successful completion of any project is in Safety Training.
Building safe attitude is also a key factor in maintaining a safe
workplace. Safety is, and always will be a team effort, safety starts
with each individual employee who comes on site and concludes with
everyone leaving safe and healthy at the end of the day and
eventually to rejoin their families.

LOCKOUT/TAGOUT- SLIDE 67 OF 67

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