Definitions
Purpose & Procedure
Verification, Release, & Policy
Site Specific
Authorized Specific
100
Employees or contractors whose job requires them to operate or use equipment on which maintenance or servicing is being performed under the LOTO procedure
Who is an Affected Person?
100
To prevent injury or death that can be caused by the unexpected release of energy
What is the purpose of LOTO?
100
Once all devices, locks, and tags have been installed it is essential that de-energization must be.........
What is Verified
100
Anytime personnel are standing or working above, below, or inside the mold parting line area (Other than normal parting line wipe downs- door open feet secure to the floor or on a stand no higher than 30” working through door.)
What is requires electrical lockout of Hydraulic Motors
100
- Mechanical - Electrical - Hydraulic - Pneumatic - Chemical - Thermal - Gravity - Other
What is Energy Sources
200
Any person who performs LOTO on equipment or machinery in order to do maintenance or servicing of that equipment
Who is an Authorized Person?
200
Performing machine maintenance/set up, when removing a guard or entering a machine and it does not need to be running, electrical system repairs or installation, maintenance or installation of piping systems, valves, or regulators where there is a potential for release of fluids, gasses or pressure
When should you use LOTO?
200
The wrong equipment being locked out and verficiation not being completed
What is the cause of many people being injured or killed each year?
200
Tool Setup - Screw and Barrel removal - Clearing blocked Feed Throats - Removal of stuck parts- (Major jam requiring a tool) - End of arm robot change - Hot runner maintenance - Tooling/mold maintenance - Disconnecting any air, hydraulic or water lines require full LO/TO
What is Requires full Lockout of equipment
200
1. Notify employees 2. Shutdown Equipment 3. Isolate Energy 4. Attach Lockout Device 5. Release Stored Energy 6. Verify Lockout
What is the six steps for Equipment Specific Lockout
300
The placement of a lock and tag on an energy isolating device to ensure the safety of personnel and to prevent the unexpected release of energy
What is Lock Out Tag Out (LOTO)?
300
Turn off equipment, machinery, or process
What is the normal shutdown procedure?
300
- Lockout locks with only one key per lock - Lockable valve handle covers - Multi-clip lock attachments - "Plug Huggers" for cord and plug equipment - Lockable breaker clips - Lockable light switch covers
What is some of the LOTO equipment that should be READILY availble for authorized employees?
300
- Minor tool changes and adjustments, and other minor servicing activities, which take place during normal production operations, are not covered by this standard if: - They are routine, repetitive, and integral to the use of the equipment for production. - Must be done during production time, not during PM’s or times not designated as production - The work is performed using alternative measures which provide effective protection (verified functional interlocked doors).
What is does not require lockout
300
Immediately after applying lockout devices, the authorized employee must ensure all potentially hazardous stored or residual energy is - relieved - disconnected - restrained - otherwise safe
What is Step 5: Store Energy Release Procedure
400
Testing or actually trying the system or equipment controls to assure the correct energy isolating device(s) has been shut off and locked
What is Tryout or Verification?
400
Each energy isolating device used (i.e. disconnect boxes, breakers, valves, etc) Each incidental or secondary utility isolating device Each stored energy blocking device when such energy cannot be dissipated
Where should you apply a lockout device, lock, and lockout tags?
400
Failure to comply with LOTO procudures will result in disciplinary action up to and including termination of employement
What is the disciplinary policy for violating LOTO procedures?
400
Used as alternate protection for items that are considered minor work, there shall be a method of challenging to verify proper function.
What is Interlocks
400
Before starting work on a machine or equipment that is locked or tagged out, the authorized employee must verify that the machinery or equipment is actually isolated and de-energized by trying to start the machine.
What is Step 6: Verification or Try
500
A device that uses a lock to assure that an energy isolating device stays in a safe position (i.e. multiple lock clips, chains, valve handle covers, electrical plug covers, etc)
What is a Lockout Device?
500
Trapped compressed air, steam, gasses, hydraulic fluids, spring action devices, and gravity
What are types of stored energy?
500
- All personnel clear of equipment - All work completed - Obstructions, debris, tools have been cleared from the equipment - All electrical components are enclosed or properly covered - All guards, covers, and safety devices have been reinstalled - All incidental/secondary utilities have been restored - Remove locks, tags, and lockout devices - Turn operation controls to the "on" position and verify proper operation of the system/equipment.
What is the procedure to release LOTO and return to normal operation?
500
- Equipment that is Out of Service; - Reason the equipment is Out of Service; - If applicable, conditions under which the plant or equipment can be used safely; - Name of the person completing the tag; and - Date
What is the Out of Service Procedure
500
- Employee must inform supervisor of Maintenance Manager of statues of equipment - Employee, Supervisor or Maintenance Manager will put on a red long term lock on the machine and note the transfer on the Lockout Log - Employee will remove his personal lock - Key will be placed in Key lock box in the Maintenance shop - Oncoming personnel will request key from Maintenance or Supervisor - Employee will review statues of equipment - Employee will install personal lock on equipment per Lockout Procedures - Employee will remove long term lock from equipment and sign it back in on lockout log
What is Unserviceable equipment with no personnel or shift transfer procedure or long term lockout procedure
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