LOTO (Lockout/Tagout)

LOTO (Lockout/Tagout) is a safety procedure used in industry and research settings to ensure that dangerous machines are properly shut off and not accidentally turned on during maintenance or servicing. The following are the steps involved in LOTO.

1. Preparation: Before starting the LOTO procedure, identify the equipment that needs to be locked out or tagged out, and ensure that all employees who will be involved in the procedure have been trained in LOTO procedures.
2. Notify Affected Employees: Inform any employees who may be affected by the LOTO procedure, including those who operate the equipment and those who work in the area.
3. Shutdown Equipment: Shut down the equipment using the normal operating procedures.
4. Isolate Energy Sources: Identify and isolate all energy sources that power the equipment, including electrical, mechanical, hydraulic, pneumatic, and chemical energy sources.
5. Lockout and Tagout: Apply lockout and tagout devices to each energy source to prevent the equipment from being accidentally turned on. A lockout device is a physical device, such as a padlock, that is attached to the energy isolation device to prevent it from being turned on. A tagout device is a warning tag that is attached to the energy isolation device to warn employees not to turn on the equipment.
6. Release Stored Energy: After the energy sources have been isolated, release any stored energy that could pose a hazard to employees.
7. Verify Isolation: Verify that all energy sources have been isolated and that the equipment is no longer capable of operating.
8. Perform Maintenance or Servicing: Perform the necessary maintenance or servicing on the equipment.
9. Remove LOTO Devices: After the maintenance or servicing is complete, remove the lockout and tagout devices.

There are several international standards that provide guidelines for Lockout/Tagout (LOTO) procedures. Some of the most used standards include:

1. OSHA (Occupational Safety and Health Administration) 29 CFR 1910.147 - This is the U.S. federal standard that outlines LOTO procedures for general industry.
2. ISO 12100:2010 - This is an international standard that provides general principles for the design of safe machinery and includes guidance on LOTO procedures.
3. IEC 60204-1 - This is an international standard that outlines electrical safety requirements for machinery, including LOTO procedures for electrical equipment.
4. ANSI Z244.1-2016 - This is an American National Standard that provides guidelines for the control of hazardous energy during servicing and maintenance of machinery.
5. CSA Z460 - This is a Canadian standard that outlines LOTO procedures for controlling hazardous energy in the workplace.
6. AS/NZS 3012:2010 - This is a standard used in Australia and New Zealand that provides guidelines for electrical installations in workplaces, including LOTO procedures. 

 

Machine Safety Audit Checklist

As per the European Standard EN ISO 12100:2010, "Machine safety" is defined as the implementation of measures to reduce or eliminate the risk of harm to people who interact with a machine or its associated equipment during its lifecycle, including the phases of design, manufacture, installation, use, maintenance, and disposal. The standard emphasizes the importance of considering the entire lifecycle of a machine, from the initial design through its eventual disposal, and of addressing all potential hazards and risks associated with the machine to ensure that it is safe to use.

"Essential Standards for Machine Safety: A Comprehensive List "

• ISO 13849-1:2015 - Safety of machinery - Safety-related parts of control systems - Part 1: General principles for design
• ISO 12100:2010 - Safety of machinery - General principles for design - Risk assessment and risk reduction
• IEC 62061:2005 - Safety of machinery - Functional safety of safety-related electrical, electronic and programmable electronic control systems
• ANSI B11 series - Safety standards for various types of machinery, including presses, robots, and woodworking machinery
• EN 60204-1:2018 - Safety of machinery - Electrical equipment of machines - Part 1: General requirements
• EN ISO 13850:2015 - Safety of machinery - Emergency stop - Principles for design
• EN ISO 14119:2013 - Safety of machinery - Interlocking devices associated with guards - Principles for design and selection
• ANSI/RIA R15.06-2012 - Industrial Robots and Robot Systems - Safety Requirements
• AS 4024.1:2019 - Safety of Machinery series, including general principles, guards, control systems, and risk assessment.

Conducting a machine safety audit is important for several reasons:

• Ensuring compliance with regulations and standards: By conducting a machine safety audit, organizations can ensure that their machines are compliant with relevant regulations and standards, such as OSHA, ISO, or other local regulations.
• Identifying hazards and risks: A safety audit can help identify potential hazards and risks associated with the use of machines, allowing organizations to take necessary steps to mitigate those risks and prevent accidents or injuries.
• Improving safety culture: Regular safety audits demonstrate an organization's commitment to safety and help create a safety culture. It sends a message to employees that safety is a top priority and helps promote safe behavior's.
• Reducing downtime and maintenance costs: By identifying potential safety issues early, safety audits can help reduce downtime and maintenance costs associated with machine breakdowns or accidents.
• Enhancing productivity: Safe machines can operate at optimal efficiency without causing disruptions due to accidents or breakdowns.

In today's fast-paced industries, machines play a crucial role in increasing productivity and efficiency. However, with their benefits come the potential hazards that can endanger the safety of the workers. Therefore, it is essential to implement safety measures to protect the workers from machine-related accidents. Here are some key components of a machine safety checklist that can help improve safety in your workplace:

Safety Devices and Guards:

• Check if all the required safety devices and guards are in place and functioning properly. Ensure that they are maintained, adjusted, and checked for defects. Guards should be securely attached and prevent access to dangerous parts of the machine. Emergency stop buttons or other emergency devices should also be installed.

Electrical Safety:

• Make sure that the electrical system of the machine is properly grounded. Ensure that all electrical connections and components are properly insulated and protected. Check if all electrical panels and enclosures are properly marked and secured.

SOP (Standard Operating Procedures):

• Check if written operating procedures are available for the machine. Ensure that the procedures are updated regularly, clear, concise, and easy to understand. Make sure that the procedures are being followed by the operators.

Training for Employees:

• Ensure that all employees have been trained on the proper use of the machine. They should also be trained on the hazards associated with the machine and the necessary safety precautions. Refresher training sessions should be conducted periodically.

Risk Assessment:

• Conduct a risk assessment for the machine. Identify and evaluate the hazards associated with the machine. Implement the necessary risk control measures.

Danger Signs:

• Post danger signs in visible locations on and around the machine. Make sure that the signs are easily understandable, in good condition, and properly maintained.

Slip, Trip, and Other Hazards:

• Ensure that the floor around the machine is clean and free of debris. Spills should be promptly cleaned up. Use slip-resistant materials on the floor surface. Maintain appropriate lighting levels to avoid tripping hazards.

Leakage and Abnormal Sound:

• Check for any visible leakage from the machine or its components (e.g., hydraulic, pneumatic, coolant, lubricant, fuel). Observe for abnormal sounds or vibrations during operation. Immediately report, investigate, and address any leaks or abnormal sounds.

By implementing these key components of a machine safety checklist, you can improve safety in your workplace and ensure that your workers are protected from potential hazards.

 

Why 5S for Safety?

The 5S methodology is an essential component of "lean" practices for establishing a secure and efficient workplace. Maintaining a clean and orderly facility is crucial for ensuring the safety of all employees while on the job.

By arranging spaces logically, organizing tools and materials, and implementing regular cleaning routines, individuals can perform their tasks with ease and minimize the risk of accidents such as tripping, slipping, or experiencing ergonomic injuries.

1) Sort

1. Identify and segregate the items needed / not needed
2. Keep only the items you absolutely need 
3. Get rid of the unnecessary items

Safety highlights for Sort

1. To ensure a safe workplace, it's important to identify and remove any hazardous items like broken tools, unsafe ladders, and sharp/pinch points that could harm people during work or cleaning activities. 
2. Conducting a Risk Analysis can help spot potential hazards and reduce the risk of accidents. 
3. It's also necessary to define who should use certain equipment or areas to make sure only qualified individuals like powered industrial truck drivers or electronic testing personnel can access them.

2) Set In Order

1. To ensure efficient and safe workflow, it's essential to define and mark off specific areas, such as aisles, workspaces, and work-in-progress areas. 
2. It's important to properly classify and arrange everything in these areas, following color codes, safety, and ergonomic rules, and considering frequency of use. This way, items can be easily accessed and quickly stored. 
3. Also, make sure everything is returned to its designated "home" when not in use. 
4. To enhance visual management, use labels and signs, line markings, and tool foam to help organize and identify items.

Safety highlights for Set in order

1. When setting up a work area, it's important to prioritize safety by properly laying out and installing equipment, trolleys, devices, work-in-progress, tools, products, and anything else in a safe manner. Additionally, storing everything properly can help reduce the risk of injury from sharp or pinch points during work or cleaning activities.
2. After installing and storing everything safely, update the Occupational Risk Analysis to ensure that the new arrangement is safe for potential hazards like trips, pinches, or shocks. For example, make sure there are no cables on the floor or sharp corners of metal sheets unprotected. If any risks cannot be avoided, use high-visibility markings to highlight them.
3. Finally, define how the workplace should be used in case of non-routine activities, such as where and how to store parts during disassembly. This way, everyone knows what to do to maintain a safe work environment.

3) Shine

1. Maintaining cleanliness and proper condition of the workplace is crucial for a safe and efficient work environment. This includes continuously cleaning and maintaining the floor, periodically cleaning the walls, windows, ceilings, and substructure, and ensuring everything is kept in good condition and functioning properly.
2. To achieve this, it's important to conduct daily Shine activities, including inspection and routine maintenance, to keep the equipment and surroundings clean and in great shape. 
3. Additionally, eliminating sources that contribute to the need for increased cleaning can help improve efficiency and safety. 
4. Lastly, keeping information and documents up-to-date with the right version can also help ensure that everything runs smoothly. 

Safety highlights for shine

1. Maintaining an effective 5S system is important for a safe and efficient workplace. Conduct daily checks that include safety checkpoints and ensure that cleaning materials are approved for human health and compatibility with materials and machines. 
2. Evaluate cleaning operations for safety and wear the necessary personal protective equipment (PPE), such as safety glasses and gloves, to avoid chemical exposure to eyes.
3. To prevent slips and falls, put floor cleaning operations under control, such as by using warning signs or closing off the area during cleaning. 
4. Additionally, evaluate and remove/prevent safety risks based on the findings from daily checks, to maintain a safe and healthy work environment.

4) Standardize

1. To ensure an effective 5S system, the first three S's - Sort, Set in Order, and Shine - need to be followed with clear rules and guidelines. These rules should be documented in visual work instructions and a daily 5S check plan, which can help to maintain the effectiveness of the system.
2. Preventive maintenance techniques should also be implemented to maintain the 5S system, and these should be documented in a visual preventive maintenance plan. To ensure that the system is standardized, visual management tools should be used to separate normal from abnormal.
3. In addition, it's important to follow organization guidelines to maintain a consistent and professional look and feel. Monthly audits should be performed by management staff to evaluate the effectiveness of the 5S system, and the results of these audits should be visualized to identify areas for improvement.

Safety highlights for standardize

1. Safety is a critical component of any workplace, and it's important to take proactive measures to ensure that all employees are working in a safe environment. To achieve this, safety should be highlighted on all documents and work instructions, and a standardized daily safety check should be implemented to identify potential hazards and risks.
2. Visual warning signs should also be used to indicate high-risk areas or points, and regular safety assessments and walk-throughs should be conducted to identify and address any potential hazards.
3. One effective way to prevent safety risks is through safe work design, which involves designing processes and systems that minimize the risk of injury or accidents. This approach can help to reduce the likelihood of accidents and improve overall safety in the workplace.

5) Sustain for sustain

1. To ensure that the 5S system is maintained and becomes a part of the workplace culture, it's important to ensure that everyone respects the rules daily. This can be achieved by implementing a management system such as SIM to track and monitor 5S activities and progress.
2. Recognizing and celebrating successes is also important and can help to motivate employees to maintain a high level of 5S. A reward system can be put in place to acknowledge and incentivize good 5S practices.
3. With consistent effort and focus, 5S activities can become a habit and ingrained in the workplace culture. This can lead to less effort required to maintain the 5S level, as it becomes a natural part of the way things are done in the workplace.

Safety highlights

1. Adhere to safety rules during daily operations
2. Incorporate 5S into safety walks
3. Encourage a "See it, do it" mentality to immediately correct 5S deviations and remove risks
4. Include noncompliance with safety standards as a disqualifying factor in any 5S competitions
5. Only reward perfect 5S adherence.