Lockout Tagout compliance not only saves workers life but also helps in enhancing the productivity at the site. In our previous article, we have discussed Lockout Tagout Compliance and common challenges in LOTO compliance. In this article, we’ll put information on how to overcome LOTO compliance challenges, which are listed below.
Comprehensive Training Programs:
Both personnel who may be impacted by the usage of these techniques and those who are authorized to perform LOTO procedures must receive training. An effective LOTO training program should include instruction on how to properly lock out or tag out equipment, as well as how to operate LOTO devices and other safety equipment. It should also include information about the dangers associated with the equipment being worked on, as well as precautions to avoid accidents and injuries.
Cultural Change Initiatives:
In a workplace, to make safety a priority, it needs to start at the top level. When managers, leaders, and employers show that they care about safety, workers understand its importance and follow in management’s footsteps. Also, rewarding safety through appreciation, awards, or certificates is highly motivating not only for the receiving employee but for his co-workers as well.
Investment in Safety Technology:
A safe workplace is a productive workplace. The employer must invest in employees’ safety and well-being, whether it is through implementing procedures or providing the right LOTO devices. Specific LOTO devices like de-electric padlocks, cylinder locks, or quality valve lockouts help make the workplace safer and more productive.
Regular Audits and Continuous Improvement:
Regular audits help identify gaps in safety procedures through thorough inspections of machinery, equipment, and work processes to identify potential hazards. This ensures that all safety protocols are up-to-date and the plant is meeting the standards set by international bodies.
Case Studies and Success Stories:
#CASE 1 –Â During repairs on a pipeline carrying hot oil, employees followed proper lockout tagout procedures. After completion, all locks were removed, and the system was returned to its operating state. However, control-room personnel were unexpectedly instructed to start up the system five hours earlier than planned. Without knowledge of the early start-up, two supervisors decided to inspect the repairs themselves. They failed to implement any lockout/tagout procedures for the inspection and did not inform control-room personnel of their decision. When the system was started as instructed, oil flow resumed through the pipe, resulting in the fatalities of the two supervisors.
This case shows that all employees, not just those authorized to repair, must be notified about the maintenance process. Any personnel must attach his/her own lock before entering any hazardous areas.
#CASE 2 –Â A tragic incident occurred involving a 52-year-old welder who lost his life after being crushed by a hydraulic door on a metal shredder. The fatal accident happened as the employee was trying to clear a jammed piece of metal from the hydraulic door. Unfortunately, the object causing the obstruction fell away unexpectedly, causing the door to abruptly close on the worker. It was determined that the energy in the system had not been properly released, and the door had not been secured in an open position.
This case shows that even though it might have seemed like a minor task to remove the log, proper isolation procedures were required. If any task involves putting any part of the body in harm’s way, safety precautions must be used.
Conclusion
Lockout Tagout is not just for following compliance but to ensure worker safety and continued productivity. Protection from life-altering accidents like amputations, burns, broken bones, and losses can be avoided by taking calculative measures.
A LOTO process has both financial and ethical incentives when it is implemented properly and adheres to the standards set by OSHA. The above-mentioned accidents must inspire companies to have a zero-accident workplace with the right safety guidelines and procedures. When the company focuses on worker safety, it receives payback in the form of increased productivity, more profits, boosted morale, and a good brand reputation. Get in touch with us today at E-Square to empower your employees with the right tools and procedures needed to achieve ‘Zero Harm’ and address the complexities of your plant.
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