5 Tips for Improving Your Lockout/Tagout Program

Lockout/tagout (LOTO) is a procedure developed to protect employees and other workers from the unexpected startup of machinery under maintenance or repair. A successful LOTO program ensures that the faulty machinery is entirely shut down, has been tested for residual energy, and will not be started again until the proper time. Lockout procedures are implemented to prevent serious and fatal injuries from hazardous energy. Improving your lockout/tagout program enhances workplace safety and compliance.

While OSHA requires these programs, the internal LOTO programs vary by company. For this reason, many companies could benefit from auditing and improving their procedures. Follow these tips if you want to design an effective lockout/tagout program.

The Importance of the Lockout/Tagout Program

A robust lockout/tagout program is a regulatory requirement and a cornerstone of workplace safety. It protects your employees from the unexpected energization or startup of machinery and equipment, preventing injuries and fatalities. Ensuring all devices are properly locked and tagged out during maintenance and repair operations is vital for safety and security.

Signs Your Lockout/Tagout Program Needs Updating

Recognizing the signs that your lockout/tagout program needs updating is crucial for maintaining workplace safety and compliance. An outdated or ineffective program can lead to increased risks around machinery and equipment, putting employees in danger and potentially leading to costly downtime. Here are key indicators that it’s time for an update:

• Outdated or Worn-Out Lockout Tags: If your lockout tags and safety lockout tags are faded, damaged, or don’t reflect the latest information, it’s a clear sign that your program needs attention. Modern, durable, self-laminating lockout tags can withstand harsh conditions and ensure clear communication.
• Recurring Safety Incidents: Increased accidents or near misses related to equipment operation suggest that your current lockout/tagout procedures are insufficient.
• Non-Compliance Issues: Regular audits might reveal gaps in compliance with industry regulations, indicating the need for updated LOTO devices and practices.
• Feedback from Employees: Workers struggling to operate or find suitable devices for lockout/tagout could indicate the need for more intuitive solutions or training.
• Changes in Machinery or Processes: Any significant updates to your facility’s equipment or operations require a corresponding lockout/tagout program update to address new hazards or procedures.

By addressing these signs promptly with updated lockout tagout tags, safety devices, and procedures, you can ensure the safety and security of your employees, maintain compliance, and minimize the risk of operational interruptions.

5 Tips to Improve Your Lockout/Tagout Program

Improving your lockout/tagout program enhances workplace safety and compliance. Here are five actionable tips:

Select the Correct Lockout/Tagout Devices

Every workplace is unique, which means the LOTO devices needed will vary from one company to the next. Choosing the right LOTO devices is crucial. They must be suitable for the specific machinery and compliance requirements.

You should create a complete list of the machines and electrical components needing lockout/tagout devices. This list often includes industrial machines, circuit breakers, switches, push buttons, plugs, and valves. Once you have this list, you can get the specific lockout devices required for your company. 

Now that you have the locks in hand, you need to keep a system for organizing them and making them easily accessible to employees. A lockout station is a great way to keep devices organized. Ensure you sort the locks by size and color so workers know which lock will suit their needs.

Clearly Mark All Isolation Points

Isolation points must be clearly marked with lockout tags to ensure everyone understands where and how to properly lock out equipment. As part of a successful lockout/tagout program, you should visibly identify all isolation points or the places where machines are removed from energy sources. The tags or labels used should be permanent and highly durable.

Design a Detailed Training Program

A LOTO program is completely useless if employees do not understand or know their specific roles. Therefore, you will need to design an effective training program that details which tasks need to be completed during a lockout/tagout process and which worker should complete those tasks.

Each employee should be assigned a role as an authorized worker, affected worker, or other. Authorized employees are involved in the process of locking out equipment or machinery. Affected employees are those whose work is affected by the lockout. Other employees are individuals who work near the equipment or machinery but do not touch it.

While OSHA requires lockout/tagout training once a year, it’s best to revisit training more than this to ensure safety is maintained throughout the year. Make sure you document when and where the training was conducted, as well as who was involved and what was covered so that your company can quickly identify any gaps in training.

Document All Procedures

Documenting all lockout/tagout procedures ensures all employees know what to do if a machine or equipment needs to be locked out. These written procedures should detail precisely how a machine should be shut down and the hazardous energy isolated. It should also cover how to place and remove LOTO devices.

Once completed, these procedures should be posted next to the relevant piece of equipment or machinery. Including images or graphics of the lockout steps with the written instructions may be beneficial.

Review Your Program Periodically

Be sure to revisit your lockout/tagout program from time to time. Was it effective when a machine was locked out for maintenance or repair? Was there any confusion about the process? Evaluations like these can help you determine if your program needs to be improved. You can also follow the inspection guidelines provided by OSHA to discover areas for improvement.

Ongoing Benefits for Regularly Improving Your Lockout/Tagout Program

Regularly updating your lockout/tagout program is not just about compliance; it’s a strategic investment in workplace safety and operational efficiency. Your organization can continuously refine this critical safety protocol to achieve significant, ongoing benefits. These enhancements not only safeguard your employees against potential hazards associated with machinery and equipment but also foster a culture of safety that permeates every level of your operation. Here’s how your organization stands to benefit:

• Enhanced Safety and Reduced Workplace Injuries: Regular lockout/tagout program updates significantly lower the risk of accidents and injuries. Incorporating the latest safety devices and lockout tagout tags ensures that all equipment is secured against unauthorized or accidental activation, keeping your employees safe.
• Improved Compliance with Safety Regulations: Staying up-to-date with lockout/tagout updates means your program will align with the latest compliance standards. This proactive approach minimizes the risk of legal issues and fines, ensuring your practices meet or exceed regulatory requirements.
• Increased Equipment Efficiency and Longevity: A well-maintained lockout/tagout program helps prevent improper use and handling of machinery, reducing wear and tear. This extends the life of your equipment and optimizes its performance, contributing to smoother, more efficient operations.
• Boosted Employee Morale and Productivity: When employees see that their safety is a priority, it boosts morale and builds trust. A secure workplace is more productive, as workers are more focused and engaged when they feel protected.
• Cost Savings: Regularly improving your lockout/tagout program can lead to significant cost savings. Avoiding accidents and ensuring machinery operates correctly reduces the need for expensive repairs or replacements and decreases potential downtime.

By focusing on these ongoing benefits, your organization enhances its safety protocols and reinforces its commitment to protecting its most valuable asset—its employees.

Enhance Your LOTO Program With Lockout/Tagout Tags

Designing and improving a lockout/tagout program can be daunting and complicated. When purchasing lockout/tagout tags, they shouldn’t be. That’s why many companies turn to LEM Products, Inc. for all their tags.

We make it easy to find the specific tags you need for your LOTO program, including danger equipment locked out tags, and we ensure our tags meet all ANSI and OSHA standards. Order your lockout/tagout tags today! And don’t forget to check out our selection of equipment maintenance tags and options for custom industrial tags.