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LOCKOUT/TAGOUT

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Purpose and Scope

The purpose of this procedure is to establish a comprehensive lockout/tagout program that is designed to prevent injuries caused by unexpected activation of hazardous energies including any unintended motion, energization, startup, or release of stored energy.

This procedure establishes expectations regarding safe methods of controlling energy during servicing and/or maintenance of machines and equipment and is consistent with corporate guidelines.

This procedure applies to all operations. It is also a requirement for all contractors and vendors as outlined herein.

Below is a listing of typical activities in which energy control procedures apply (alternative methods can be used for performing work involving the control of hazardous energy, provided it is consistent with the requirements of this policy):

Adjusting

Lubricating

Cleaning

Maintaining

Constructing

Removing

Dismantling

Repairing

Erecting

Servicing

Inspecting

Setting Up

Installing

Testing*

Jam Clearing

Troubleshooting*

Note: Testing and troubleshooting are normally done by qualified technicians using proper PPE and voltage-rated tools while equipment is energized.

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Key Elements of the Guideline

The guideline addresses the following key elements:

  • Procedures for conducting and complying with 1910.147
  • Responsibilities for executive management, DC management, maintenance management, the safety process manager, the team members, and the contractors working on site
  • Training that will be conducted for authorized and affected team members, as required, on an annual basis
  • Maintenance tech work task audits and interviews conducted jointly by the maintenance and safety process managers
  • Annual program auditing that will be conducted by the Safety Management Action Team (SMAT) under the guidance of the maintenance manager and safety process manager

The appendices provide full-size templates to be duplicated and maintained by maintenance.

Lockout/Tagout Procedure All Distribution Centers

The attached procedure is the minimum standard that applies to all maintenance operations in all distribution centers.

Factors Used To Determine DC Compliance

The following are the factors that will be used to determine DC compliance with this process during division safety audits:

Definitions

Affected Team Member: Any team member whose job requires him/her to operate or use a machine or equipment on which servicing or maintenance is being performed under lockout/tagout, or whose job requires him/her to work in an area in which such servicing or maintenance is being performed

Authorized Team Member: Any team member who is authorized by management to lockout/tagout a piece of equipment to perform servicing or maintenance on equipment; an affected team member becomes an authorized team member when that team members duties include performing servicing or maintenance on that piece of equipment or machinery

Designee: A person designated in writing by the distribution center manager, maintenance manager, or operations manager to perform specific functions

Energized: Connected to an energy source or containing residual or stored energy

Energy Isolating Device: A mechanical device that physically prevents the transmission or release of energy, including but not limited to the following:

  • A manually operated electrical circuit breaker
  • A disconnect switch
  • A manually operated switch by which the conductors of a circuit can be disconnected from all ungrounded supply conductors, and in addition, no pole can be operated independently
  • A line valve
  • A block or any similar device used to block or isolate energy

Note: Pushbuttons, selector switches, and other control circuit type devices are not energy-isolating devices.

Lockout: Placement of a lockout device on an energy isolating device in accordance with established procedures, ensuring that the energy isolating device and the equipment being controlled cannot be operated until the lockout device is removed

Lockout Device: Device that uses a positive means, such as a lock, to hold an energy isolating device in the safe position and prevent the energizing of a machine or equipment; included are blank flanges and bolted slip blinds.

Zero Energy Procedure: A procedure for eliminating energy from equipment and machinery prior to maintenance, repair, servicing, or modification that contains the following identification of all energy sources:

  1. De-energization
  2. Lockout
  3. Tagout
  4. Relief of stored energy
  5. Testing and verification

Normal Production Operations: Utilization of a machine or equipment to perform its intended production function

Other Team Member: Any team member not covered under authorized or affected but still needs a general awareness of the lockout/tagout program

Qualified Technician: Person who has completed a formal program of training (either in a classroom or on-the-job) and qualification and is familiar with the:

  • Hazards associated with work with electricity
  • Skills and techniques needed to distinguish exposed live parts from other parts of electrical equipment
  • Clearance/approach distances required and the corresponding voltages to which the qualified person will be exposed
  • Safety-related electrical work practices pertaining to their respective job assignments
  • Electrical requirements included in operating and maintenance procedures, including lockout/tagout/try

Safe Position: The specific position of an energy isolating device that prevents unexpected energization of the equipment (i.e., open/closed, de-activated, blocked, removed); safe position of energy isolating devices must be identified with the equipment-specific procedure

Servicing and/or Maintenance: Workplace activities such as constructing, installing, setting-up, adjusting, inspecting, modifying, maintaining, and/or servicing machines or equipment; includes lubrication, cleaning or jam clearing of machines or equipment, and making adjustments or tool changes, where team members may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy

Shift: A shift is considered a normally scheduled shift plus any authorized overtime

Setting-Up: Any work performed to prepare a machine or equipment to perform its normal production operation

Tagout: Placement of a tagout device on an energy isolating device in accordance with established procedures to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed

Tagout Device: Prominent warning device, such as a tag and a means of attachment, which can be securely fastened to an energy isolating device in accordance with established procedures to indicate that the energy isolating device and the equipment being controlled may not be operated until the tagout device is removed

Test: Temporary re-energization of equipment and removal of lockout/tagout devices to check operation or positioning prior to completion of the work; allowed only during the limited time necessary and only on the affected components; after completion of the testing, the equipment must be de-energized and all lockout/tagout requirements resumed

Try: Physical act of trying to start or energize equipment immediately after lockout/tagout has been completed to verify isolation and release of potential energy; person qualified to operate the equipment or machinery must accomplish this operation

  • Equipment interlocks, where applicable, must be verified that they are not engaged in order to prevent the isolation.
  • Attempts to "try" a local field switch on equipment controlled automatically or remotely (such as by DCS systems) may not serve as an adequate means to verify isolation.
  • If work is being performed on electrically operated devices in such a manner that failure to de-energize the circuit could put workers in contact with live circuits, voltage will be tested by a qualified technician to verify that the power is de-energized.
  • Other methods may be necessary to determine if other types of energy sources have been isolated. In each case, a qualified person must determine the absence of all potential energy before work is started.

Verification: Process of proving the lockout/tagout is effective, identical to "try"; it is an OSHA required step

Zero Energy State (ZES): Physical state of equipment and machinery following complete de-energization and verification implementation of the lockout/tagout/try procedure

Lockout Tagout Principles

It is mandatory that all personnel comply with the restrictions and limitations of this procedure. Failure to comply will result in disciplinary action, up to and including, dismissal or contract termination.

No individual will attempt to start, energize, or use a piece of equipment that has been locked out or attempt to remove a lockout device and tag under this program, except as provided by this procedure.

When a task requiring access to a machine, equipment, or process requires power, alternative methods of energy control must be used on a risk assessment and will provide effective personnel protection. An electrical safety plan, if applicable, must be used provided these plans have been developed by team members performing the task and have been reviewed and approved by the maintenance manager or his/her designee in accordance with Electrical Safe Work Practices guidelines.

All lockout(s) will require a general or individual lockout/tagout locks and a "DANGER-DO NOT OPERATE" tag to be applied to the equipment at the energy isolating device. Lockout/tagout devices at a DC will be standardized in at least one of the following criteria: color, shape, size, or specific markings and will be used for no other purpose other than lockout/tagout. A "DANGER-DO NOT OPERATE" tag can only be used without a lockout lock when a lockout device cannot be physically applied to an energy-isolating device. In these situations, effort must be made to identify a method to reconfigure the energy isolating device so that a lock can be applied or to otherwise secure the device (e.g., by using chains, cable ties, etc.) in an effective isolating position. All DCs must ensure that all new electrical devices purchased at the DC are compatible with the standard lockout/tagout devices.

NOTE: After January 2, 1990, whenever replacement or major repair, renovation, or modification of a machine or equipment is performed, and whenever new machines or equipment are installed, energy isolating devices for such machine or equipment will be designed to accept a lockout device.

NOTE: Warded locks are not as secure as pin-tumbler locks, and warded locks can be removed using the wrong key. If a lock set is used, the master key for the locks must be destroyed.

All lockout/tagout locks and lockout devices must be capable of withstanding exposure to the associated work environment conditions. Tags will be attached to the lock or equipment with a material having the general design and characteristics equivalent to a one-piece, all environment tolerant nylon cable tie, which is non-reusable and attachable by hand. The tie must be self-locking, and require a minimum unlocking strength of at least 50 lbs. for release.

Each authorized team member will receive at least two lockout/tagout locks and/or have access to tags and protective materials and hardware required (hasps, cable ties, chains, etc.) to perform isolation of energy.

All equipment energy isolating devices will be clearly identified in a uniform manner. They will be labeled or marked, unless they are located and arranged so that their purpose is clearly evident. The identification must be of a consistent format within each DC and will include the following:

  • Equipment supplied from
  • Energy type
  • Magnitude (e.g. 480V, etc.)

For machines, equipment, or systems that are out of service and there is no short-term plan to place the equipment back into service, red "DANGER-DO NOT OPERATE" tags CANNOT be used to keep the equipment out of service. A separate yellow "CAUTION-DO NOT OPERATE" tag must be used instead.

When electrical system grounds need to be applied, they will be the last devices applied and the first devices to be removed from the lockout/tagout. Only qualified electrical technicians will apply grounding devices. If grounding devices are used, they will be listed on the lockout/tagout form as energy isolating devices.

No team members are authorized to work on switchgear or voltages above 480 VAC. Such work should be performed by an outside contractor. Lockout/tagout applies to all sources of energy, including, but not limited to, the energy sources listed below:

Primary and Secondary Energy Sources

  • Electrical
  • Pneumatic
  • Hydraulic
  • Gases
  • Water
  • Steam
  • Chemical/Coolant
  • Radiation
  • Magnetic

Stored Energy Sources

  • Rotation (mechanical motion that can cause equipment movement): Flywheels, circular blades, etc.
  • Gravity (suspended material or parts that will move when energy is disconnected): Cranes, conveyors, elevators, etc.
  • Mechanical Energy (stored mechanical energy that can cause machine or equipment movement): Compressed or extended springs, etc.
  • Thermal Energy (extreme heat above 140 degrees Fahrenheit or cold below 41 degrees Fahrenheit): Boilers, chillers, etc.
  • Electrical Energy (stored electricity): Batteries, capacitors, etc.
  • Hydraulic Energy (residual pressure): Accumulators, lines, cylinders, etc.
  • Pneumatic (residual pressure): Storage or surge tanks, lines, etc.
  • Gas (residual pressure): Pipes, tanks, etc.
  • Water (residual pressure or stored): Pipes, tanks, etc.
  • Steam (residual pressure): Pipes, boilers, etc.
  • Chemicals/Coolant (residual pressure or stored): Pipes, tanks, containers, etc.

Equipment-Specific Lockout Tagouts

Each DC will develop equipment-specific lockout/tagout procedures for each individual piece of equipment except when ALL the following criteria are met:

  • The machine or equipment has no potential for stored or residual energy or re-accumulation of stored energy after shutdown, which could endanger team members (e.g., compressed springs, capacitors, suspended parts).
  • The machine or equipment has a single energy source, which can be readily identified and isolated (e.g., a single electrical disconnect switch, pneumatic/hydraulic source).
  • The isolation and locking out of that energy source will completely de-energize and deactivate the machine or equipment.
  • A single lockout device will achieve a locked-out condition (including a single hasp with multiple locks or group lock box for single lock point).
  • The lockout device is under the exclusive control of the authorized team member performing the servicing or maintenance.
  • The servicing or maintenance does not create hazards for other team members.
  • The employer, in using this exception, has had no accidents involving the unexpected activation or re-energization of the machine or equipment during servicing or maintenance (verify through records check).

NOTE: The allowance of this exception requires a thorough review of the equipment and verification of the conditions listed. The intent of the equipment-specific lockout/tagouts is to create a master list of all possible isolation points that can be referenced for all future lockout/tagouts.

Each equipment-specific lockout/tagout procedure will contain the following elements:

  • Energy sources and magnitude
  • Notification to affected team members
  • Preparation for shutdown
  • Machine or equipment shutdown
  • Machine or equipment isolation
  • Lockout/tagout device application
  • Stored energy dissipation or other verification requirement
  • Verification of isolation
  • Notification of affected team members
  • Release from lockout/tagout

DCs will use an equipment-specific lockout/tagout procedure template or similar (provided it meets the requirement of this policy). By completing this form, the requirement for developing equipment-specific lockout/tagout has been satisfied for that piece of equipment.

Equipment-specific lockout/tagout procedures must be readily accessible to authorized team members (kept in the maintenance office files, attached to work orders, attached to the equipment where feasible, computer database, etc.) and will be developed in local language.

Alternate means must be in place to make these procedures readily available in the event of loss of accessibility due to flood, loss of power, fire, etc. Alternate means include:

  • Electronic copy stored at a separate location
  • CD backup for use on laptop computer
  • Hard copies

Group Lockout Tagout

When service and maintenance requiring de-energization of a system/equipment is performed, and more than one authorized team member is involved in the maintenance action, a procedure that affords all the authorized team members a level of protection equivalent to that provided by the implementation of a personal lockout/tagout device is required.

NOTE: Use of a Group Lockbox or "GLB" is an acceptable method of meeting this requirement. Padlocks, keys, and tags are stored in the "GLB". It is removed and used to lockout the equipment. The authorized team member in charge of the work removes this padlock and tag, places them on the equipment, and then locks the key in the "GLB" using their personal lock. Each individual involved in the maintenance action places their individual lock on the lockbox. The key locked in the "GLB" can only be removed once ALL of the personal locks have been removed from the "GLB".

Group lockout/tagout devices will be used in accordance with this procedure including, but not limited to, the following specific requirements:

  • Primary responsibility and authority is vested in the maintenance manager or his/her designee for their authorized team members working under the protection of a group lockout or tagout device.
  • Provision for the maintenance manager or his/her designee to determine the exposure status of their authorized team members with regard to the lockout and tagout of the system or equipment.
  • When more than one authorized team member is involved, assignment of overall job-associated lockout/tagout administration will be to one maintenance function manager or his/her designee designated to coordinate affected team member work forces and ensure the continuity of protection.

When a multiple-hole hasp lockout/tagout device is used to accommodate the number of authorized team members involved, the following steps are required:

  1. Each authorized team member places their lock on the multiple lock hasp.
  2. Each authorized team member working on the equipment or system being locked out will verify the effectiveness of the lockout/tagout.
  3. Upon completion of the work, each authorized team member working on the equipment/system is to remove their individual lockout/tagout lock and tag from the multiple-hole hasp.

NOTE: The authorized team member in charge of the maintenance action must walk down the area of the just-completed work to ensure the area has been properly cleared and guards have been replaced, that the area has been cleaned, and that it is ready for service. In addition, affected team members are to be notified prior to the start of the job and prior to restoration of the equipment.

Temporary Removal of Lockout Tagout Locks and Tags

The following steps must be followed by authorized team members in situations when lockout/tagout devices must be temporarily removed from a machine or piece of equipment for testing or positioning of the machine/equipment:

  1. Survey the work area to ensure that non-essential items have been removed and that all machine components are operationally intact.
  2. Notifying all team members who were working on the affected equipment that the removal of lockout/tagout locks and red "DANGER-DO NOT OPERATE" tags and subsequent equipment testing will occur and checking that all team members and affected team members are removed from the area or safely positioned.
  3. Verify that the controls are in an off or "safe" position.
  4. Remove lockout/tagout locks and red "DANGER-DO NOT OPERATE" tags.
  5. Energize as needed and proceed with testing/positioning.
  6. After testing/positioning is complete, notify affected team members, de-energize the system again, verify system equipment de-energization and isolation, and re-apply lockout/tagout locks and the "DANGER-DO NOT OPERATE" tags until the maintenance or repair task is completed.

Devices Not Capable of Being Locked Out

A risk assessment will be documented for any devices not capable of accepting a lock.

NOTE: A durable deterrent in the form of a chain, cable tie, or other appropriate device will be used to secure the energy-isolating device when practical.

After January 2, 1990, whenever replacement, major repair, renovation, or modification of a machine or equipment is performed, and whenever new machines or equipment are installed, energy isolating devices for such machine or equipment will be designed to accept a lockout device.

Additional measures must also be taken to demonstrate full team member protection, such as the removal of an isolating circuit element, blocking of a controlling switch, opening of an extra disconnecting device, or the removal of a valve handle to reduce the likelihood of inadvertent energization.

Team members must be trained to recognize the limitations of tags.

Red tags applied without locks will only be allowed on equipment specifically identified by the hazard analysis that CANNOT be physically locked out in some manner. Every effort should be expended to avoid this situation. All authorized team members must be informed of the specific equipment that cannot be locked out, and the training program must be modified to ensure all team members understand the meaning of a red tag on a piece of equipment without a lock. The maintenance manager must be informed to facilitate a request for modification. Additional isolation is required for this type of protection to be applied.

These special conditions of nonlock equipment will be clearly described on the equipment-specific lockout/tagout procedure.

Alternative Methods

When tasks specified are not servicing and/or maintenance activities and are routine, repetitive, and integral to the process, alternative methods of energy control may be used. The alternative methods are based on risk assessment and will provide effective personal protection.

Minor tool changes and/or adjustment, setup, jam clearing, part location, and cleaning are examples of tasks for which alternative methods may be used unless the following conditions exist:

  • Bypassing or removing of guards or safety devices
  • Placement of any body part in the machine, equipment, process, or circuit operating area where work is actually performed upon the material being processed (point of operation)
  • Where an associated danger zone exists during a machine operating cycle
  • No alternative method assigned to the task
  • Task-specific training not provided

Alternative methods are acceptable if the reason for operator intervention (i.e., performance of the task) is to sustain the machine, equipment, and process or circuit continuity within the nominal performance range and output quality. This usually occurs when the machine, equipment, process, or circuit is operating normally, and the need for periodic service is predictable based on operating experience and product demands. Also, the tasks do not require that the machine, equipment, process, or circuits be taken out of the operational mode to accomplish them.

Plug and Cord Equipment

When equipment to be worked on is plug- and cord-connected, it is not necessary to attach a lockout/tagout locks and red "DANGER-DO NOT OPERATE" tags to the plug after it is removed if both of the following are true:

a. The cord is visible to and under the exclusive control of the authorized team member, and

b. The plug and cord equipment has a single source of electrical energy.

If one or both of the above mentioned conditions fails to exist, then the plug must be locked in a plug canister or similar lockout device, and a lockout/tagout lock and a "DANGER-DO NOT OPERATE" tag must be attached to the plug.

Shift or Personnel Change

The maximum permitted duration for lockout/tagout is a normal shift (plus any authorized overtime) or the duration of the task, whichever is shorter. Lockout/tagouts lasting longer than one shift require an Immediate Hand-Off between the current authorized team member and the oncoming authorized team member.

As part of shift turnover, oncoming and off-going authorized team members must complete a face-to-face hand-off. The maintenance manager or his/her designee will list all ongoing lockout/tagouts when a group lockout/tagout is in place or by an authorized team member during a regular lockout/tagout.

Upon turnover, the responsibility for active lockout/tagouts is automatically transferred to the oncoming authorized team member.

The current authorized team member must remove his/her individual lock, and the oncoming authorized team member must immediately replace it with his/her own individual lock. The oncoming authorized team member must verify the lockout/tagout is still effective by performing the verification steps contained in the equipment-specific lockout/tagout procedure.

If the equipment will be out of service for an extended period of time, the authorized team member must remove their personnel lock and replace it with a general lock with a "Caution Do Not Operate" tag attached. The key for this lock should be placed under the control of maintenance manager or his/her designee until it is needed to remove the lock for replacement with an authorized team member personnel lock and "Danger Do Not Operate" tag when work on the equipment starts again. The maintenance manager or his/her designee will use standard key control procedure for this key, and an annotation of the date the general lock is used will be made in the remarks section of the work order generated for the task.

Abandoned Locks and Tags

In case the signer of the tag cannot be located, the maintenance manager or his/her designee may authorize the removal of the lockout/tagout lock(s) and red "DANGER-DO NOT OPERATE" tag(s) after all possible attempts have been made to locate the team member. The attempts made to locate the team member, and the fact that someone other than the authorized team member removed the lock must be documented by using the "Emergency Tag/Lock Removal" form.

Upon his/her return to the site and before resuming work at the site, the signer of the tag must be notified by his/her supervisor that the lockout/tagout has been released.

Contractors

Prior to the contractor performing any work involving the control of hazardous energy, the DC will provide a copy of this procedure to every contractor.

Contractors will be subject to the lockout/tagout procedure.

All outside contractors will be briefed on this procedure and on any special or unique hazards that are related to the equipment that the contractor will be working on. It is a policy to require all outside contractors to be familiar with, and follow the requirements of this procedure. The DC and contractor will each designate a representative responsible for determining the relationship, responsibilities, and obligations regarding hazardous energy control before starting work or providing service.

All contractors will verify that their team members performing work under lockout/tagout have been trained to meet regulatory requirements. Any additional requests for documentation will be promptly submitted by the contractor to work at a DC.

Authorized team members should isolate equipment and systems; however, the contractor or their designated team members MUST be present while the isolation is performed. Contractors or their designated team members will place their own personal locks and tags on the appropriate lockbox or energy isolating device that authorized team member has locked out and be afforded the opportunity to verify the effectiveness of the lockout/tagout. In the event of an isolate requirement where the contractor is more knowledgeable of the equipment or system, for example the distribution switchgear, they should be allowed to perform the isolation, however a authorized team member MUST be present to witness the isolation.

Senior Vice President- Logistics

  1. Sets the standards to which policies are to be developed.

Regional Vice President-Distribution Centers

  1. Provides guidance and direction in the development, distribution, implementation, and audit of these procedures
  2. Ensures the completion of an annual review of this program and communicates changes to the distribution centers

Distribution Manager

  1. Reviews audits by the maintenance and reliability manager

Maintenance and Reliability Manager

  1. Directs the development of procedures at the companys distribution centers to ensure compliance with federal, state, and local codes
  2. Audits the distribution centers to ensure the compliance with corporate directives and policies

Manager of Operations

  1. Directs the maintenance manager or his/her designee in the development of the distribution centers lockout/tagout procedures
  2. Develops administrative procedures to ensure compliance with applicable federal, state, and local codes
  3. Ensures annual audits of the responsible managers to ensure compliance with corporate directives and policies
  4. Oversees the maintenance manager or his/her designee in providing annual training for all authorized team members on the procedural steps necessary to safely lockout/tagout energy sources
  5. Oversees the maintenance manager or his/her designee in developing lockout/tagout, shutdown, and startup procedures for each piece of equipment; representative sample of like procedures are re-evaluated and updated on an annual basis or when a modification/change or work practice necessitates the re-evaluation and/or updating of a procedure
  6. Oversees the maintenance manager or his/her designee in developing and updating a list of authorized team members
  7. Ensures all affected team members and authorized team members understand the procedure and their individual duties under this program
  8. Ensures that all contractors are familiar with and understand their responsibilities under this procedure
  9. Ensures lockout/tagout audit findings are tracked and corrected in a prompt manner
  10. Takes prompt disciplinary action for any violation of this procedure

Safety Process Manager

  1. Ensures and participates with maintenance in audits of maintenance techs conducting LOTO
  2. Jointly conducts audits of the overall LOTO program with maintenance and operations staff as directed by SMAT
  3. Participates in risk assessments with maintenance and operations representatives

Maintenance Manager

  1. Ensures all authorized team members understand their responsibilities under this procedure and the lockout/tagout they will be working under
  2. Ensures that all portions of this procedure are implemented properly
  3. Ensures any violation of this procedure is reported to the DCM, MO, and safety process manager
  4. Conducts periodic audits of authorized team members and contractors implementing the lockout/tagout procedure
  5. Maintains documentation of all audits
  6. Ensures audits are conducted on a representative number of the departments authorized team members
  7. Discusses with the authorized team members the lockout/tagout program to determine their understanding of the proper procedures and practices used to provide lockout/tagout protection on various pieces of equipment
  8. Ensures that all authorized team members and contractors who service equipment follow all the steps of this lockout/tagout program
  9. Ensures the training of all authorized team members on the procedural steps necessary to safely lockout/tagout energy sources
  10. Ensures that all training is documented and maintained by human resources
  11. Oversees the development of lockout/tagout, startup, and shutdown procedures for all affected equipment; lockout/tagout procedures are re-evaluated on an annual basis
  12. Oversees the development and maintaining an updated list of authorized team members and provides this list to the distribution center manager

Authorized Team Members

  1. Complies with all parts of this procedure
  2. Reports any violation of this procedure to the maintenance manager and/or designee
  3. Obtains and reads the lockout/tagout procedures and/or alternative procedures before starting a job
  4. Obtains all necessary isolation devices indicated on the procedure prior to starting the job
  5. Identifies all hazards before starting the job
  6. Notifies all affected team members before initiating or terminating lockout/tagout or alternative procedures
  7. Applies isolation devices as intended within their design capacity
  8. Immediately notifies the function manager and maintenance manager or his/her designee of any undetected hazard(s)/exposure(s) and works with them to provide a solution of how to eliminate or isolate them
  9. Recommends to the maintenance manager or his/her designee ways to improve these procedures
  10. Uses the proper personal protective equipment and tests after isolating an energy source to verify that all hazardous energy sources are controlled
  11. May not remove another authorized team members lock/tag/isolation device or interferes with a lockout/tagout procedure, unless the lock removal procedure is authorized by the maintenance manager or his/her designee or area manager and the procedure for lock removal are followed

Affected Team Member

  1. Complies with this program
  2. Knows the requirements of this lockout/tagout procedure and his/her responsibilities with meeting those requirements
  3. Provides for an orderly shutdown/startup of his/her equipment, as requested, for lockout/tagout
  4. May not remove a lock or tag being used for lockout/tagout for any reason
  5. Never attempts to restart a piece of equipment or machine/process that have been locked out except under the direct supervision of the person holding the lockout; may be required to verify that the repair or maintenance is being accomplished and to determine its suitability to be returned to service; equipment may then be restored to the lockout condition pending completion of the maintenance and/or repair

Training

All team members will receive lockout/tagout training in accordance with the training program requirements. This training will be tracked by Human Resources.

In addition to maintaining the training records, Human Resources, the maintenance manager or designee will maintain the original attendance sheets and a copy of the training materials in a central location. The training records will be reviewed at least annually to identify individuals requiring refresher training.

Auditing

An annual audit of the LOTO procedure will be conducted by the maintenance function manager or his/her designee and the safety process manager and reported to the SMAT. The audit will be documented on lockout/tagout audit form or similar. Each audit form will be maintained for at least five years after the performance of the audit.

While conducting the lockout/tagout audit:

  1. A representative number of active lockout/tagouts will be visually verified to ensure that the appropriate procedure has been correctly applied.
  2. All other authorized team members will be questioned to ensure understanding of their duties and responsibilities under the policy.
  3. A random number, but at a minimum four (4) training records of authorized and affected team members will be checked to ensure their qualification is current as per the requirements of the training program.

If, during a periodic audit, a discrepancy or procedural inadequacy is found, steps will immediately be taken to determine the reason for, and the corrective action necessary to remedy the discrepancy. A record will be maintained of all findings.

The distribution center manager or his/her designee will certify that the periodic audits have been completed.

Risk Assessment

Risk assessment is an analytical tool consisting of a number of discrete steps intended to ensure that hazards are properly identified and the means to control those hazards are identified.

Identify Hazards: Hazards associated with each piece of equipment, such as mechanical, electrical, thermal, pneumatic, hydraulic, radiation, residual or stored energy, motion, fuels, and human factors should be considered. Consideration should include human error, management system deficiencies, and foreseeable improper use of equipment.

The risk assessment is the responsibility of the maintenance department to complete with assistance from the safety. Maintenance personnel performing the risk assessment must be qualified in the construction, installation, and operation of the equipment.

Lockout/Tagout Locks and Tags

Table 1 summarizes the application and use of the three different types of tags and associated locks covered in this program.


Table 1: Lock Usage

Complete the Hazard Analysis for the Equipment

To develop an equipment specific lockout/tagout procedure, a detailed equipment hazard analysis must be completed to identify all hazardous energy sources in the equipment. This involves reading the equipment prints, technical manuals, and a visual inspection of the equipment itself to identify any hazards that might not be readily identified from any other source. An example of this would be a disconnect switch that is mounted in a manner that it cannot be reached easily or without additional equipment.

Use the form in Equipment Specific Risk Assessment Worksheet for each affected piece of equipment at the distribution center.

Create the equipment-specific lockout procedure by filling in the necessary areas of the template in Equipment Specific Lockout/Tagout Template.

Complete the Equipment Specific Lockout Procedure Template

To fill out the equipment specific lockout/tagout procedure, insert the name and tag number of the equipment as requested in the title line and statement of purpose section. Not all sections will apply to all equipment; if a section is found that does not apply, it is acceptable to fill the section in with "Does Not Apply," "Not Applicable," or "N/A."

In the Electrical Hazards sections, list all magnitudes of electrical energy feeding the equipment and the control device for each. If the control device is not easily identified, be as descriptive as possible when describing the location of the control device.

In the Mechanical Hazard section, list all types of mechanical energy including gravity and all means to control/release the energy such as a valve or a block.

Affected personnel will vary according to shift, time during shift, and current production schedules. If possible, avoid listing individuals in this section unless necessary.

List the shutdown steps for the equipment, even if is as simple as going to an operator control station and pressing the stop button. Any manufacturer or local shutdown procedures used for this equipment should be listed here.

Be as descriptive as possible when describing the location and placement of the lockout devices. Use any installed labels, identifying signs, etc. Do this for both electrical and mechanical sections.

In the control/release of stored energy, list the type and magnitude, if available and the method used to release any stored energy, if applicable.

Verification of the lockout/tagout is an attempt to operate the equipment and verify the effectiveness of the lockout/tagout. This should not be confused with the testing required for a zero energy state. This test operate applies to both electrical and mechanical.

Release from lockout tagout should include any normal start up procedure used to turn on the equipment.

Assign a number to the lockout/tagout procedure in accordance with Equipment Specific Lockout/Tagout Numbering Protocol.

Validate the Procedure

  • Print out a copy of Lockout/Tagout Procedure Coversheet and attach to the developed procedure.
  • Fill in the Procedure Title section using the procedure title from the procedure.
  • Fill in the Procedure Number section using the number from the procedure.
  • Fill in the submitted line with the name of the person who developed the procedure.
  • Fill in the date using the calendar date the validation occurs.
  • Assign two maintenance personnel to validate the process, one maintenance person to perform the procedure, and a second person to witness the validation.
  • If the procedure is correct as written, the maintenance personnel will sign in the appropriate blank on the coversheet and forward to the maintenance manager for approval.
  • If the procedure is incorrect or needs additional information, return to the developer with the corrections and/or additions annotated. Once the corrections have been made, the complete validation process must be restarted.
  • The maintenance manager will review the procedure, and if it acceptable, will print, sign, and date in the appropriate blocks. If the procedure is unacceptable, the maintenance manager will return the procedure to the drafter with comments.
  • The procedure and coversheet, when signed, will then be filed and the procedure, minus the coversheet, will be printed or copied and used for the specific equipment.

HazardDescription

Hazard TypePotential HazardYesNoComments
1. EntanglementCan anyones:

  • Hair, clothing, gloves, necktie, jewellery, cleaning brushes, rags, or other materials become entangled with moving parts of the equipment or materials in motion?
2. CrushingCan anyone be crushed due to:

  • Material falling off the equipment?
  • Uncontrolled / unexpected movement of the equipment or its load?
  • Lack of capacity for the equipment to be slowed, stopped or immobilized?
  • The equipment tipping or rolling over?
  • Parts of the equipment collapsing?
  • Coming in contact with moving parts of the equipment during testing/inspection/use/maintenance/cleaning/repair?
  • Being thrown off or under the equipment?
  • Being trapped between the equipment and material or fixed structures?
  • Other factors not mentioned?
3. Cutting, Stabbing, and PuncturingCan anyone be cut, stabbed or punctured due to:

  • Coming in contact with sharp or flying objects?
  • Coming in contact with moving parts of the equipment during testing, inspection, operation, maintenance, cleaning or repair of the equipment?
  • The equipment, parts of the equipment or work pieces disintegrating?
  • Work pieces being ejected?
  • The mobility of the equipment?
  • Uncontrolled or unexpected movement of the equipment?
  • Other factors not mentioned?
4. ShearingCan anyones body parts be:

  • Sheared between two parts of the equipment, or between a part of the equipment and a work piece or structure?
5. FrictionCan anyone be burnt, gain abrasions etc, due to:

  • Contact with moving parts or surfaces of the equipment, or material handled by the equipment?
6. StrikingCan anyone be struck by moving objects due to:

  • Uncontrolled or unexpected movement of the equipment or material handled by the equipment?
  • The equipment, parts of the equipment or work pieces disintegrating?
  • Work pieces being ejected?
  • The mobility of the equipment?
  • Other factors not mentioned?
7. High-Pressure FluidCan anyone come into contact with:

  • Fluids under high pressure in normal use, in the event of equipment failure, or misuse of the equipment?
8. ElectricalCan anyone be injured by electrical shock or burnt due to:

  • The equipment contacting live electrical conductors?
  • Equipment working close to electrical conductors?
  • Overload of electrical circuits?
  • Damaged or poorly maintained electrical leads/cable?
  • Damaged electrical switches?
  • Water near electrical equipment?
  • Lack of isolation procedures?
  • Other factors not mentioned?
9. ExplosionCan anyone be injured by explosion of:

  • Gases, vapours, liquids, dusts or other substances triggered by the operation of the equipment or by materials handled by the equipment?
10. High Temperature or FireCan anyone:

  • COME INTO CONTACT WITH OBJECTS AT HIGH TEMPERATURE?
  • Be injured by fire?
11. SuffocationCan anyone be suffocated due to:

  • Lack of oxygen, or atmospheric contamination?
12. Slipping, Tripping, and FallingCan anyone using the equipment, or in the vicinity of the equipment slip, trip or fall due to:

  • Uneven or slippery work surfaces?
  • Poor housekeeping, such as shavings in the vicinity of the equipment, spillage not cleaned up?
  • Obstacles being placed in the vicinity of the equipment?
  • Other factors not mentioned?
13. Falls From HeightsCan anyone fall from a height due to:

  • Lack of a proper work platform?
  • Lack of proper stairs or ladders?
  • Lack of guardrails or other suitable edge protection?
  • Unprotected holes, penetrations, or gaps?
  • Poor floor or walking surfaces, such as a lack a slip-resistant surface?
  • Steep walking surfaces?
  • Collapse of the supporting structure?
  • Other factors not mentioned?
14. Temperature (Thermal Comfort)Can anyone suffer ill health due to:

  • Exposure to high or low temperatures?
15. Other HazardsCan anyone be injured or suffer ill-health from exposure to:

  • Chemicals?
  • Toxic gasses or vapors?
  • Fumes?
  • Dust?
  • Noise?
  • Vibration?
  • Radiation?
  • Other factors not mentioned?
16. Equipment Use and SuitabilityAre there any identified hazards relating to:

  • The equipments suitability for its actual and intended tasks?
  • The environmental conditions and terrain in which the equipment may be used?
  • Any foreseeable abnormal situations or fluctuations of operating conditions?
  • The load capability of any equipment required to lift and move people, equipment, and materials?
  • The suitability of any secondary backup system to support the load?
  • All control systems (including guarding and communication systems)?
  • The suitability and condition of all accessories?
  • The adequacy of access and egress?
  • The suitability and stability of the equipment and its support systems?
  • The location of the equipment and any impact of the equipment on the design and layout of the areas of use?
  • Persons working with or in the vicinity of the equipment?
  • Operator competencies and certification?
  • Other factors not mentioned?

Equipment Specific Lockout/Tagout Template

Lockout/tagout for (insert equipment noun name, tag number/identifying tag number, etc), procedure number (insert number).

Statement of Use

This procedure is used to place the (insert equipment name/tag number) in a locked out/tagged out condition for maintenance. Electrical and/or mechanical lockout/tagout can be accomplished using the procedure. Failure to follow this procedure could lead to disciplinary action.

Electrical Hazards

List ALL electrical hazard(s) by magnitude and the control device for that hazard.

Hazard TypeControl Device

Mechanical Hazards

List ALL mechanical hazard(s) by type, magnitude (if possible), and the control device/method to control/release the hazard.

Hazard TypeControl Device or Method

Affected Personnel Notification

  • First Shift Monday through Friday
  • Second Shift Monday through Friday
  • Third Shift Monday through Friday
  • Weekend Shift Saturday and Sunday

Release from Lockout/Tagout

  1. Complete inspection of work area.
  2. Ensure all personnel are safely positioned or have moved from the area.
  3. Remove all lockout/tagout devices applied to place the equipment in a lockout/tagout condition, and place the energy control device into the position required for normal operation of the equipment. (This list is identical to the list in the placement of lockout/tagout device(s); however it will include the position of the energy control device after lockout/tagout removal).
  4. Notify the affected personnel (notification of the same personnel used in the shutdown step).
  5. Start the equipment.
  6. Test the equipment to verify operation.
  7. Notify affected personnel that equipment has been restored.

Equipment Specific Lockout/Tagout Numbering Protocol

Each lockout/tagout will have a unique identifier assigned that provides document, site, system, and skill level for the procedure. For example, LT-J-CRM0001A would indicate a lockout/tagout document, applicable for Jupiter, ASRS system, and a skill level of Mechanical, revision A. Use the following information to assign numbers to the lockout/tagout procedures.

The first two (2) characters are the document type.

Document TypeDocument
LT Lockout/Tagout Procedure
PM PM Procedure
RP Repair Procedure
OP Operating Procedure

The 3rd character is the DC.

DC1 Character Code
Anderson A
Berkeley B
Flagstaff F
Jupiter J
Lehigh Valley L
Moreno Valley M
Mt Vernon V
Orlando O
Perrysburg P
Waxahachie X
Windsor, CT C
Windsor, WI W
Woodland D

The fourth and fifth characters are the system type.

System CodeSystem Type
AG AGV
CV Conveying
CR ASRS/AKL
FA Facilities
LT Lift Trucks
SO Sortation
TO Tote Buffer
TT Turrent trucks
CA Carousel

The last character indicates the revision number and starts with A and continues through Z.

Lockout/Tagout Procedure Coversheet Lockout/Tagout Procedure Coversheet

When signed, this coversheet, along with an original copy, must be filed for future reference.

Emergency Red Do Not Operate Tag/Lock Removal Form-Template

NOTE: Use this form if work on equipment is complete, but red 'DO NOT OPERATE tags and locks remain on the equipment, and the person who has placed them has left the site and is unable to remove them.

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