“LOTO” You Are In the Right Class In keeping with the western theme of this years ACPA Short Course, lets take a look at LOTO and interject one of America’s favorite actors – CLINT We will stretch it a bit, as CLINT has been in many types of movies but he broke into acting through westerns… Here is how this will go – There will be a movie title missing a word on several slides. Please raise your hand if you can complete the title and there will be a reward forthcoming.

Strategies to Keep Workers Safe Lockout Tagout LOTO “It's a hell of a thing, killing a man. Take away all he's got and all he's ever gonna have”. Will Munney, Unforgiven “In the of Fire”… Strategies to Keep Workers Safe

The Importance of LOTO “Thunderbolt and ???”… LOTO incidents happen in a lightning flash It is estimated that 3 Million workers maintain heavy industrial equipment every day.

The Importance of LOTO “The ????? Pool” … LOTO is critical to life and death Approximately 120 fatalities and 15,000 disabling injuries each year from insufficient lockout systems

The 6 Basics of A Solid LOTO Program Strong Policy w/teeth Precise, Detailed Procedures Consistent / Frequent Training Monitoring emphasis Investigation Process Strict, consistent enforcement “…Enforcer”

“??? Impact” Strong Policy w/ “Teeth” Zero Tolerance? Well written policy is critical Frequent / thorough communication of policy New employee orientation to plant Annual training for everyone Regular routine monitoring while work on going Well defined exception process

Precise Detailed Procedures With a policy that has “teeth” there will be very technical items related to the event that may will be questioned… Where do I put my lock? Was power verified to be “off” prior to entry? How / was employee trained properly? In what order was the procedure exercised? Was the employee in the “danger zone”? Was the procedure correct? Key Consideration: What was the routine used by employees to complete that procedure within the plant?

Precise Detailed Procedures “A Perfect ???” Each Step “written in blood” “…Work” Philosophy of “Absolute …” Identify power sources hydraulic, pneumatic electrical gravity, residual energy Identify “upstream” power (examples) Feedbelt to pipe Weigh hopper to mixer

Precise Detailed Procedures Reviewed systematic basis (yearly, quarterly, etc.) or; as equipment is altered Posted or available At the machine For every machine or piece of equipment that is not simply “plug in” or “battery only”

8 Steps Per Procedure Let everyone know a procedure is about to begin “Turn off the Radio” – Stop the machine Turn off / Isolate ALL power sources Place locks to prevent restart of ALL power sources Secure the key(s) Attempt to start the machine or equipment Complete Maintenance or work activity Restore equipment to Service

Consistent and Frequent Training Physically at the machine (walk through) In the classroom During actual work activity (to test understanding) Reinforcement of policy contents All new Employees “…Rookie”

Monitoring Emphasis Managers and Supervisors should monitor LOTO processes frequently while work is in progress Not as a method to “Hang’ Em ???” but to: Coach, anticipate, and reinforce training

Investigation Process Since the policy is strict and has “teeth”, consider: Suspension while investigation takes place More than one reviewer of the incident Recommendations of others Witness statements If “overlooked” it could be “Heartbreak???” at a later date… Ensure that a “True ???” has been committed

Investigation Process Factors that should not be considered Length of service “Importance to Operation” “Likeability” above all CONSISTENCY must be maintained

Summary Prevention of Death and Dismemberment is the key reason for Lockout Tagout Five elements are critical to a solid LOTO program Strong Policy w/teeth Precise, Detailed Procedures (and documentation) Consistent and Frequent Training (and documentation) Monitoring emphasis Investigation Process Strict, consistent enforcement