Business-Smart Lockout/Tagout Choices Offer More than OSHA Compliance

Besides risking OSHA citations and fines, it's no secret that preventable lockout/tagout (LOTO) incidents can cause worker injuries, damage equipment and facilities, disrupt production and even put your company out of business. However, no company wants to spend more than they need to nowadays, especially on “non-productive” items that don't directly add to the bottom line.

The good news is there are several things you can look for beyond basic lockout functions when evaluating and selecting LOTO energy isolation devices, padlocks, tags and signs that can simplify your LOTO, save time and energy as well as money, and also help ensure that A) devices get used and B) that lockouts are effective.

Several major manufacturers offer a full selection of products to meet virtually every LOTO need, but all devices are not created equal; some work more effectively than others. And some lockout environments pose special challenges that if not addressed, potentially could render certain devices ineffective. We will focus on important device differences, workplace environment and real-world worker scenarios and point out plusses and minuses to help guide and expedite your LOTO device search.

DOING THE JOB RIGHT

Along with OSHA requirements such as effective, durable and identifiable lockout devices and activities, several additional factors to consider are noted below, followed by examples of how OSHA and related issues could impact your choices.

Simplify LOTO with multiple-application devices. Look for energy isolation products that can be used with more than one type of switch, breaker or valve. With fewer items to inventory and fewer items for workers to carry, there is less chance for confusion. And, importantly, less chance of a worker trekking to a lockout point with a 1-inch device only to discover that he needs a 2-inch device and either having to make the trip again or worse, deciding to proceed without locking out the energy source.

Ease of use

It's been said, “If it's easy to use, it will get used.” Some lockout devices may be difficult to close or hard to fit onto or around items that need to be locked out. Such situations not only frustrate workers, but can result in less-than-effective lockout — or tempt the worker to skip the procedure altogether.

Space savers

While space-saving devices require less shelf and toolbox space, the primary objective here is to look for device designs that more easily accommodate space limitations that workers may encounter at various lockout points.

Reusability

This suggestion focuses on LOTO environmental issues (chemicals, temperature, etc.) relating to signs, tags and labels, especially those that carry a common message (e.g. DANGER!) along with variable day-to-day worker identification and application info.

Dual-edged durability

Keep in mind that “durability” in LOTO means not only the strength of devices themselves, but also their ability to withstand harsh environmental conditions such as high temperatures or contact with chemicals used in plant processes, cleaning and maintenance.