Requirements for using Safety Padlock include following relevant safety standards (such as OSHA), ensuring each worker uses a unique padlock with a clear identification tag, being trained on lockout procedures, regularly checking padlock status, notifying relevant personnel before maintenance, and strictly enforcing the lockout process to improve the safety of the work environment and reduce the risk of accidents.
1. Develop and Document Lockout Tagout Procedures or Policies
The first step in successfully implementing lockout tagout is to develop and document an equipment energy control policy/program. Written lockout documentation establishes and explains the elements of the program.
It is important to consider not only OSHA guidelines, but also the customized requirements of your employees to ensure they can understand and apply the plan to their work.
The plan is not a one-time fix; it should be reviewed annually to ensure it is still applicable and effective in protecting employees. Developing a lockout plan should be a joint effort at all levels of the organization.
2. Write machine/task-specific lockout tagout procedures
Lockout procedures should be formally documented and clearly identify the equipment covered. Procedures should detail the specific steps required to shut down, isolate, block and immobilize equipment to contain hazardous energy, as well as the steps for placing, removing and transferring locked/tagged equipment.
In addition to compliance, we recommend that best practice procedures be developed that include machine-specific photographs identifying the point of energy isolation. These photos should be posted at the point of use to provide clear, visual instructions to employees.
3. Identify and label energy isolation points
Locate and mark all energy control points (valves, switches, circuit breakers and plugs) with permanently placed standardized labels or tags. Remember, these labels and tags should be consistent with the equipment-specific procedures in Step 2.
4. Lock and Tag Training and Periodic Inspection/Audit
Ensure that employees are adequately trained, processes are communicated, and periodic inspections are conducted to ensure that your program is operating effectively. Training should include not only OSHA requirements, but also your own specific program elements, such as your machine-specific procedures.
When OSHA evaluates a company's lock and tag compliance and performance, it looks for the following categories of employee training:
- Authorized Employees. Personnel who perform maintenance lockout procedures on machines and equipment.
- Affected employees. Employees who do not perform lockout requirements but use machines that are being serviced.
- Other Employees. Any employee who does not use the machine but is located in an area where the equipment is being maintained.
5. Provide appropriate lockout tagout equipment
With so many products on the market designed to help keep your employees safe, selecting the most appropriate solution for your application is key to lockout effectiveness. Once selected, it is important to document and utilize the most appropriate device for each lockout point.
6. Sustainability
Your lockout tagout program should always be continually improving, which means it should include regular reviews. By continually reviewing your program, you will create a safety culture that proactively addresses lockout tagout issues, allowing your company to focus on maintaining a world-class program. It also saves time because it prevents you from starting from scratch every year and only reacting to problems as they arise.
Not sure you can maintain sustainability costs? Programs that lack sustainability tend to be more costly in the long run because the Locked Tagging Program must be reworked every year. By simply maintaining your program throughout the year, you can enhance your safety culture and use fewer resources because you don't have to reinvent the wheel every time.
Looking at your program from this perspective, it's clear that a sustainable program can help you stay one step ahead of the curve while saving time and money.
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