OSHA promulgated the LOTO standard in 1989, nearly 30 years ago and yet...  This is the "classic failure" that brought about the LOTO standard - employee kills employee - so when your employees say it never happens, you can provide this.

At 11:57 a.m. on December 27, 2016, an employee was performing a salt flush on the line four 2,500 lb. double ribbon mixer. The employee entered the mixer after he dropped an 80 lb. bag of salt. After entering the mixer, his coworker placed another bag of salt onto the area of the mixer that had the limit switches that indicated that the mixer lids were closed. Because the machine operated via only the emergency stop button, the machine began to operate with the employee trapped inside, killing him. The employee was killed from trauma to the chest.

CLICK HERE for the case file

  1. Guide for the Control of Hazardous Energy in the Process Industries (MIRM)

  2. Why does OSHA consider a "blank flange" and "bolted slip blind" as a Lockout device?

  3. When is an "energy isolation device" "capable of being locked out"

  4. BSEE Releases Investigation Report into Platform Explosion (LOTO error)

  5. Crushed by and caught-in between machinery (TN-OSHA Inspection #1041324)

  6. Caught in Auger Fatality (TN-OSHA Inspection #1040935)

  7. Did you know... almost every single energy isolation REQUIRES a WRITTEN ENERGY ISOLATION PLAN

  8. For goodness sake - LOCK IT OUT people! (Willful w/ $70K)

  9. Even in "complex energy isolations" we MUST include specific procedures to VERIFY ZERO ENERGY of EACH isolation point (OSHRC)

  10. OSHA grants permanent LOTO variance

  11. Workers hurt when pressurized fluid escapes (LOTO Incident @ Mine)2015 OSHA LOTO activity by Industry Sectors

  12. OR-OSHA publishes "Oregon OSHA’s guide to controlling hazardous energy"
  13. ZERO energy state (ZES) means ZERO energy state
  14. LOTO Accident Data from OSHA's Preamble
  15. More LOTO Adventures
  16. MIOSHA Guidance: Minor Tool Changes and Adjustments, and Other Minor Servicing Activities
  17. LOTO and Contractors
  18. Lockout is the RULE, “minor servicing” is the exception
  19. It is Lockout OR tagout... NOT BOTH
  20. LOCKOUT/TAGOUT Methods and Sample Procedures (CAL-OSHA)
  21. Why does OSHA permit the LOTO exception ONLY on electrical cord and plug equipment?
  22. OSHA's requirement for "machine specific" LOTO procedures and the "exception"
  23. LOTO fatality while cleaning (NY FACE)
  24. From a recent OSHA citation for LOTO, yes we still have problems!
  25. LOTO Fatality - Caught in conveyor system (TN-OSHA II #28 - 2010)
  26. A traditional LOTO fatality - worker started equipment on another worker (TN-OSHA #23)
  27. Clearing up a couple of LOTO myths
  28. Palletizer kills temporary worker, 21, on his FIRST DAY of work (LOTO)
  29. OSHA takes issue with EVERY Authorized Employee having a key to the lockbox
  30. Have you ever seen/heard of this LOTO practice before?
  31. LOTO Periodic Inspections and their significance
  32. LOTO Program Suggestions from a reliable source!
  33. OSHA cites manufacturing plant for exposing workers to hazardous energy sources during machine servicing
  34. LOCK IT OUT!!! WARNING - Image may be upsetting to some
  35. Is tagging a blind flange or slip blind "tagout"?
  36. De-enerizing Stored Energies
  37. Verifying the content of lockout programs
  38. Supervision in Manufacturing - Guards & Lockout (Video)
  39. Defining Exclusive Control under LOTO activities
  40. Minor Servicing Alternative Safety Measures
  41. OSHA, LOTO and the unexpected movement of trucks
  42. Proper LOTO or a serious problem? (POLL)
  43. Verifying ZES is DIFFERENT for electrical workers!
  44. My TOP 12 Life Saving LOTO Principles
  45. Group LOTO Verification of ZES Requirements
  46. Periodic Inspections
  47. LOTO Training Requirements
  48. Shift or Personnel Changes
  49. Verification of ZERO ENERGY STATE (ZES)
  50. Tagout and Full Employee Protection (e.g. Tag Plus)
  51. Can ALL your LOTO Training needs be met by On-Line Training?
  52. LOTO on Chemical Process and Piping Systems
  53. Does your LOTO program contain "enforcement" procedures?
  54. GREAT LOTO Cartoon (VIDEO)
  55. Lock out. It takes just seconds to lose a limb (VIDEO)
  56. One of my favorite LOTO videos (VIDEO)
  57. FALSE Sense of Safety...using interlocks in Lieu of LOTO!!!
  58. We have THREE Choices to Identify our Lockout Locks
  59. Tagout vs. Lockout
  60. Company argues before the OSHRC that LOTO does not apply to their die changing activities - an analysis of a OSHRC 2009 decision
  61. Cord and Plug Equipment and "Line of Sight"
  62. Tagout vs. Lockout #2
  63. 911 Call - What REAL TRAGEDY sounds like (911 audio)
  64. Grouping equipment for purposes of conducting periodic LOTO inspections     
  65. LOTO Machine Specific Procedures

For those who manage Lockout-Tagout (LOTO) in a "processing operation" know first-hand how different LOTO is as compared to how its done in an "assembly line" style operation.  I have always picked up some "Best Practices" for LOTO at the companies I worked for over the years and as a consultant, I have seen many more at some of my world-class clients. However, I have always struggled to put all of these best practices into one comprehensive document where they all work in concert with one another; that is until some of my international clients recently shared with me... Guideline Mechanical and Process Isolations Major Hazard Standard.  This "guide", and yes it is NOT from OSHA or even a USA document, is without a doubt a MUST HAVE for any LOTO lover!  Are you looking to take your LOTO program and practices to the next level; this guide will take you there.  This guide even provides us with a very sound risk analysis on the different types of energy control methods based on the level of risk involved in the isolation - folks this is just AWESOME!  For example, here is a means to semi-quantify the risks associated with tasks and the proper means of energy isolation for said risks... this is JUST PURE SAFETY CAKE:

In OSHA's LOTO standard (1910.147) the agency included in their definition of an "lockoout device" a "blank flange" and "bolted slip blind", when in fact these device are actually "energy isolation devices".  So why would OSHA consider these devices a "lockout device"?

NOTE:  I am not in agreement with this and have never called a "blank flange" and "bolted slip blind" a "lockout device", but rather energy isolation devices.  This may seem like semantics, but it is HUGE in the world of energy control!

In the Final Rule, OSHA determined that lockout is a surer means of assuring deenergization of equipment than tagout, and that it is the preferred method. However, the Agency also recognized that tagout will nonetheless need to be used instead of lockout where the energy control device cannot accept a locking device. Where an energy control device has been designed to be "lockable", the standard REQUIRES that lockout be used unless tagout can be shown to provide "full employee protection," that is, protection equivalent to lockout. But what does OSHA consider to be "locakable"?

The Bureau of Safety and Environmental Enforcement (BSEE) has released the panel investigation report into the November 20, 2014 explosion and fatality on a platform. The explosion occurred on West Delta Block 105 Platform E, resulting in the tragic death of Jerrel Hancock.  Mr. Hancock, a Turnkey Cleaning Services supervisor, died after an explosion occurred inside the electrostatic heater treater located on the platform while the contract cleaning crew personnel were engaged in activities related to cleaning the vessel.  The five member investigation panel identified a number of failures in the application of basic safety management practices which may have contributed to Mr. Hancock’s death. The report concludes that there were apparent inadequacies in:

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