1. Here's a LOTO scenario many don't think about (Lock removal & $17K)

  2. LOTO Fatality - 38-year old welder was fatally injured while doing maintenance on a large chip conveyor (WA-OSHA Video)

  3. The classic LOTO fatality still occurs!

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

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

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

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

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

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

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

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

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

  13. OSHA grants permanent LOTO variance

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

  15. OR-OSHA publishes "Oregon OSHA’s guide to controlling hazardous energy"
  16. ZERO energy state (ZES) means ZERO energy state
  17. LOTO Accident Data from OSHA's Preamble
  18. More LOTO Adventures
  19. MIOSHA Guidance: Minor Tool Changes and Adjustments, and Other Minor Servicing Activities
  20. LOTO and Contractors
  21. Lockout is the RULE, “minor servicing” is the exception
  22. It is Lockout OR tagout... NOT BOTH
  23. LOCKOUT/TAGOUT Methods and Sample Procedures (CAL-OSHA)
  24. Why does OSHA permit the LOTO exception ONLY on electrical cord and plug equipment?
  25. OSHA's requirement for "machine specific" LOTO procedures and the "exception"
  26. LOTO fatality while cleaning (NY FACE)
  27. From a recent OSHA citation for LOTO, yes we still have problems!
  28. LOTO Fatality - Caught in conveyor system (TN-OSHA II #28 - 2010)
  29. A traditional LOTO fatality - worker started equipment on another worker (TN-OSHA #23)
  30. Clearing up a couple of LOTO myths
  31. Palletizer kills temporary worker, 21, on his FIRST DAY of work (LOTO)
  32. OSHA takes issue with EVERY Authorized Employee having a key to the lockbox
  33. Have you ever seen/heard of this LOTO practice before?
  34. LOTO Periodic Inspections and their significance
  35. LOTO Program Suggestions from a reliable source!
  36. OSHA cites manufacturing plant for exposing workers to hazardous energy sources during machine servicing
  37. LOCK IT OUT!!! WARNING - Image may be upsetting to some
  38. Is tagging a blind flange or slip blind "tagout"?
  39. De-enerizing Stored Energies
  40. Verifying the content of lockout programs
  41. Supervision in Manufacturing - Guards & Lockout (Video)
  42. Defining Exclusive Control under LOTO activities
  43. Minor Servicing Alternative Safety Measures
  44. OSHA, LOTO and the unexpected movement of trucks
  45. Proper LOTO or a serious problem? (POLL)
  46. Verifying ZES is DIFFERENT for electrical workers!
  47. My TOP 12 Life Saving LOTO Principles
  48. Group LOTO Verification of ZES Requirements
  49. Periodic Inspections
  50. LOTO Training Requirements
  51. Shift or Personnel Changes
  52. Verification of ZERO ENERGY STATE (ZES)
  53. Tagout and Full Employee Protection (e.g. Tag Plus)
  54. Can ALL your LOTO Training needs be met by On-Line Training?
  55. LOTO on Chemical Process and Piping Systems
  56. Does your LOTO program contain "enforcement" procedures?
  57. GREAT LOTO Cartoon (VIDEO)
  58. Lock out. It takes just seconds to lose a limb (VIDEO)
  59. One of my favorite LOTO videos (VIDEO)
  60. FALSE Sense of Safety...using interlocks in Lieu of LOTO!!!
  61. We have THREE Choices to Identify our Lockout Locks
  62. Tagout vs. Lockout
  63. Company argues before the OSHRC that LOTO does not apply to their die changing activities - an analysis of a OSHRC 2009 decision
  64. Cord and Plug Equipment and "Line of Sight"
  65. Tagout vs. Lockout #2
  66. 911 Call - What REAL TRAGEDY sounds like (911 audio)
  67. Grouping equipment for purposes of conducting periodic LOTO inspections     
  68. LOTO Machine Specific Procedures

Recently IN-OSHA issued citations to the nations largest grocery store chain when management at one of their retail outlets removed a contractor's LOTO lock without following their own (or the contractor's lock removal procedures).  We can get some idea as to what happened based on the citations, but bottom line... BEFORE cutting off a LOTO lock, procedures have to be followed!  It appears to be a shift change matter as well, as one manager signed off on the contractor to use their lock(s) and another manager gave the OK to cut off the contractor's lock.

A 38-year old welder was fatally injured while doing maintenance on a large chip conveyor at a commercial wood chipping facility. A new conveyor system had been installed to move wood chips from a large chipper to the yard area. The system was operational but not complete. Two workers, including a welder, were working at the in-feed end of the conveyor system which was 400 feet from out-feed end.  At the same time, two other workers were working at the out-feed end of the conveyor. The control panel, including the disconnect switch for the system, was located at the out-feed end. The conveyor was shut down for maintenance.

The workers at the out-feed end needed to move the belt a few feet to complete their work. Before starting up the conveyor, one of the workers checked to see if the other workers at the in-feed end were away from the belt. He saw one worker clear, but did not see the welder, and apparently did not know he was at the worksite, so he activated the on switch. This switch was designed to be locked out as shown in the photo on the right, but no lockout devices were in use at the time of the incident.  The welder was working below the hopper, sitting on the conveyor belt between the metal framework and the conveyor and therefore not visible from the out-feed end. When the conveyor belt was turned on, the welder was immediately pulled by the moving belt into the narrow space under the metal framework feet first, trapping him and inflicting severe crushing injuries. The fast-moving conveyor belt was on for 4-5 seconds and moved nearly 33 ft. with the welder trapped before it was shut-off. His co-workers immediately called 911 and then managed to free him. He was transported to the hospital, but died soon after.

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

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!

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