1. Hazardous Energy Control/Lockout
MESH Process Safety
December 2013

2. Background Why is this Important?
Affected 
Authorized
Production operator was attempting to tighten a bolt on a machine. The machine was not locked out. The employee bumped the start switch and the machine closed on the employee’s hand. The employee was diagnosed with a contusion (bruise) to the hand that resulted in three days away from work.

3. Background Why is this Important?
Affected 
Authorized
Production operator was cleaning grinding materials and exchanging the sander inside a buffing machine. During this activity, the worker bumped the foot-operated switch which caused the golf grip holder bar to rise up and strike the employee in the forehead. The employee received a laceration that required stitches at a local hospital.

4. Background Why is this Important?
Affected 
Authorized
Production operator adjusting a conveyor belt chain on a Seat Grinder. After removing the chain guard and making the adjustment, the employee touched the moving chain to check the chain tension. During this activity, the operator’s finger was pulled between the chain and the sprocket resulting in a crush injury/amputation.

5. Background Why is this Important?
Affected 
Authorized
A production trainer was demonstrating to a trainee the proper method of verifying set up parameters on a finish grinder. The trainee was confirming the compatibility of the valve head locator. During this activity, the trainer actuated the machine. The trainee’s finger caught in the machine resulting in a laceration.
All four incidents involved injury to a production operator.
What do these four incidents have in common??

6. Scope/Purpose
Affected 
Authorized
The hazardous energy control/lockout program establishes requirements for the control of hazardous energy
Covers maintenance and servicing tasks when unexpected activation or release of stored energy can occur
Primary purpose of the program is to furnish lockout procedures that will reduce the risk of injury to employees and contractors performing maintenance and servicing tasks on equipment

7. Definitions Affected Person
Authorized
An affected person is an individual who operates equipment or an individual who works in an area in which servicing or maintenance activities under lockout are being performed.

8. Definitions Authorized Person
Affected 
Authorized
An authorized person is an individual who is authorized to lockout a piece of equipment in order to perform servicing or maintenance activities on that piece of equipment.

9. Definitions Stored Energy
Affected 
Authorized
Stored energy is a potential hazard that still exists after a primary energy source has been locked out. For example, a pump motor for a hydraulic system may be locked out, effectively stopping fluid flow, but energy in the form of hydraulic pressure may still exist in the machine or hydraulic line. This pressure must be released before work proceeds. Hazardous energy control requires that all stored energy be controlled to ensure complete zero energy state.

10. Definitions Zero Energy State
Affected 
Authorized
Zero energy state occurs when all sources of hazardous energy have been locked out and stored energy has been released such that the possibility of unexpected activation or movement has been eliminated.

11. Definitions Energy Control
Affected 
Authorized
Energy control is the process of turning off a piece of equipment, placing a lock on each source of hazardous energy
Energy control also involves releasing stored energy in order to bring the equipment to a zero energy state
Energy control is also called “lockout”

12. Definitions Hazardous Energy
Affected 
Authorized
Hazardous energy is any level of energy present in a piece of equipment that can cause unexpected activation, start-up, or movement that can cause injury.
Types of hazardous energy include:
Electrical
Pneumatic (Pressurized Air)
Chemical (Argon,CO2,Oxygen,NaturalGas,Nitrogen)
Hydraulic (Fluids Under Pressure)
Water / Steam
Thermal (Hot or Cold)
Radiation
Stored Energy
Rotation
Gravity
Tension

13. Application
Affected 
Authorized
Lockout must be used when performing SERVICING OR MAINTENANCE on equipment when a safeguard is bypassed or when any part of the body is placed into an area where injury would result if the equipment starts unexpectedly (danger zone)
Minor servicing activities which take place during NORMAL PRODUCTION OPERATIONS do not require the use of lockout provided that the tasks are routine, repetitive, and integral to the use of the equipment for production and safeguarding or another approved method is provided to protect operators performing the task

14. Application CONTINUED
Affected 
Authorized
What is the definition of SERVICING AND MAINTENANCE?
Servicing and maintenance may include tasks such as:
Machine set-up
Adjustments
Inspections
Cleaning
Machine maintenance
Lubrication
Jam removal
Tool changes
Lockout is required when performing servicing or maintenance if a safeguard is bypassed or any part of the body is placed into a ‘danger zone’. Servicing or maintenance activities may be performed by either maintenance or production employees.

15. Application CONTINUED
Affected 
Authorized
What is the definition of NORMAL PRODUCTION OPERATIONS?
Normal production operations means using the machine to perform it’s intended production function. Work performed to prepare a machine or piece of equipment to perform its normal production operation is called set-up.
Tasks such as set-up, jam removal, and replacement of broken tools are not considered to be part of normal production operations and require lockout if a safeguard is bypassed or any part of the body is placed into a ‘danger zone’.

16. Application CONTINUED
Affected 
Authorized
Lockout is not required when performing servicing or maintenance tasks during normal production operations. Is this correct?
Lockout is not required for activities performed during normal production operations if:
The task is minor, routine, repetitive, integral to production ; and
The work is performed using alternative safeguarding methods
Alternative safeguarding methods must ensure that the employee performing the task maintains exclusive control of the method to start the machine.

17. Application CONTINUED
Affected 
Authorized
What does MINOR mean?
Minor tasks do not require the operator to remove parts or components of the equipment including access panels, belts, gears, dies or work holding devices such as collets or chucks. Additional characteristics include: - Task does not involve more than one person;
- Task performed by machine operator (not maintenance or set-up); and
- Task is conducted using tools readily available to operator.

18. Application CONTINUED
Affected 
Authorized
What does the term ROUTINE mean?
Routine means that a production-related activity must be performed as part of a regular and prescribed course of the production process or cycle. Routine tasks are those tasks that are required when the machine is operating normally. Performance of these tasks requires minimal interruption of production operations. Stopping a machine to adjust coolant flow or adjusting a workholding device on a CNC machine to ensure a dimensionally accurate finished part are examples of routine tasks performed during normal production operations. Other than stopping the machine, these tasks do not require the machine to be taken out of the operational mode.

19. Application CONTINUED
Affected 
Authorized
What does the term REPETITIVE mean?
Repetitive means that the task is repeated regularly as part of the production process or cycle. These tasks do not require that the machine be taken out of the operational mode to accomplish them.
For example, reaching into the point of operation on a rubber molding machine equipped with light curtain safeguards to remove a finished Golf Grip and then clean the mold with compressed air is a repetitive task. This task occurs during each and every machine cycle.

20. Application CONTINUED
Affected 
Authorized
What does the term INTEGRAL mean?
Integral means that the activity is inherent to and must be performed as part of the production process. These activities are necessary to allow production to continue without interruption. Activities requiring machine or equipment shutoff and disassembly, such as changing a grinding wheel or replacing a shearing die, take place outside of the normal production process and require the application of lockout.
Integral activities focus on the part or product rather than the machine or machine component. For example, multiple tool changes that occur during the machining of a single part is integral to the production process of the part. Changing cutting tools because they have reached the end of their service life is not considered integral to the production process because the tool change is machine-oriented rather that product-oriented.

21. Application CONTINUED
Affected 
Authorized
If I have determined that a minor servicing task which takes place during normal production operations is routine, repetitive and integral to the use of the machine for production operations, what types of alternate methods are acceptable means of protection in lieu of lockout?
Eaton’s preferred method of providing alternate protection for operators performing minor servicing tasks is the application of a properly designed, installed and maintained safeguarding system. Examples include, but are not limited to, interlocked barrier guards; presence sensing devices such as light curtains, laser scanners or pressure sensitive mats; and other similar devices under the exclusive control of the operator performing the task. Such devices must be integrated into the machine control system in accordance with recognized engineering practices that ensure circuit reliability.

22. Application CONTINUED
Affected 
Authorized
Can emergency stops, feed hold buttons, or key switches be used in lieu of lockout for minor servicing tasks that are routine and repetitive?
The use of simple pushbuttons, selector switches and other control circuit devices which lack a control logic as outlined above are not permitted to be used in lieu of lockout for minor servicing tasks performed during normal production operations. Control circuits can fail due to component failure, program errors, magnetic field interference, electrical surges, improper use, or lack of maintenance.

23. Application CONTINUED
Affected 
Authorized
Besides machine safeguarding, are there any other means of providing alternate protection for operators performing minor servicing activities during normal production operations? Eaton’s preferred method of providing alternate protection for operators performing minor servicing tasks is the application of a properly designed, installed and maintained safeguarding system. Other alternate methods of protection, such as monitored power system controls, must be reviewed and approved by both the site’s sub-regional EHS manager and the MESH hazardous energy control subject matter expert.

24. Application CONTINUED
Affected 
Authorized
Our production operators are required to periodically change grinding stones on the piece of equipment pictured. Would lockout be required for this task?
Yes. Lockout is required for this task because changing the grinding stone takes place outside of the normal production cycle. The machine is turned off, grinding operations stop, and tools are used to disassemble the machine to remove the stone.

25. Application CONTINUED
Affected 
Authorized
An operator is required to periodically bypass the safety system during the production cycle to verify proper machine operation. Is lockout required for this task?
Lockout not required if an alternate form of safeguarding under the exclusive control of the employee is provided. The operator in this photo is using a hand-held jog switch that allows the machine to be run at a reduced speed while standing on the safety mat. If the operator releases or drops the switch, hazardous machine motion will stop.

26. Application CONTINUED
Affected 
Authorized
Our production operators must remove safety guards to change molds on injection molding machines. Changing molds is required running a different product. Is lockout required?
Yes. Mold changing is considered a set-up task and requires lockout.

27. Application CONTINUED
Affected 
Authorized
On a weekly basis, operators must climb into the machine to remove chips. The machine is equipped with interlocked guards. Is lockout required?
Yes. Lockout is required for this task because the cleaning activities takes place outside of the normal production cycle.

28. Application CONTINUED
Affected 
Authorized
We operate several large presses in our metal fabrication plant. We use several kinds of dies in some of our larger presses and, on occasion, our maintenance personnel stand inside the guard across the back of the machine to observe/troubleshoot malfunctions of our dies. The dies must be observed while the machine is running, and our personnel must be in close proximity to the dies as they come together to locate the minute imperfections which cause malfunctions. Once the problem is identified, our personnel leave the area and lock the machine out by following machine specific procedures until the repair is made. We cannot properly troubleshoot some of our dies without the machine running and our personnel standing inside of the rear guard.

29. Application CONTINUED
Affected 
Authorized
This activity is considered inspecting the equipment and, therefore is a servicing and maintenance task. Lockout must be applied or safeguarding provided to protect maintenance personnel during the inspection activity.
Safeguarding measures may include two-hand control devices, restraint devices that prevent the employee from entering the zone of danger, video cameras that allow remote observation of the dies, or see-through barriers that allow for close inspection of the operation yet prevent introduction of the employee's body into the machine hazard area. Every employee performing these inspection tasks must be protected from exposure to the hazardous energy.

30. Application CONTINUED
Affected 
Authorized
Bosch Inspection Camera
Dewalt Inspection Camera

31. Application CONTINUED
Affected 
Authorized
Examples of production-related tasks requiring lockout:
Cylindrical Grinder
Change abrasive wheel
Change centers
Replace diamonds
Change belts
Change coolant filter
Scrape out coolant sump
Remove jammed/dropped parts
CNC Machining Equipment
Change collet/chuck
Change machining fixtures
Change cutting inserts
Remove broken tools
Pull chip conveyor
Machine cleaning
Remove jammed parts
Entry into robot cell
Entry onto AGV track area
Bar/Screw Machine
Change tools, inserts or tool holders
Change pusher tubes
Remove jams from chip conveyor
Entry into safeguards around bar pusher
Broaches
Change broach bar
Change/adjust pullers
Change fixtures

32. Application CONTINUED
Affected 
Authorized
During set-up or maintenance activities, machines sometimes have to be operated to test or position the machine. How can this be performed if the machine is locked out?
The following steps must be taken before removing locks to test or position a piece of equipment:
Remove tools and non-essential items from the equipment;
Verify that the equipment is safe to operate;
Verify that employees are safely positioned;
Remove locks and restore energy to the equipment;
Complete the testing/positioning activity; and
Reapply locks after the testing/positioning activity
The temporary removal of locks only applies for the limited time required for the testing or positioning of the machine.

33. Application CONTINUED
Affected 
Authorized
Lockout is NOT required for plug connected equipment if the equipment or tool can be unplugged.
The person performing work on the piece of equipment must unplug the equipment before beginning work
The plug must be under the exclusive control of the person performing the work

34. Partial Energy Work Permit
Affected 
Authorized
There may be situations when a piece of equipment must be partially energized to perform a task
A Partial Energy Work Permit must be utilized to authorize such activities
Work on partially energized equipment is only allowed when it is absolutely necessary for energy to be present
Convenience or time savings may not be used as justification
The Partial Energy Work Permit must be completed electronically. Handwritten copies are not permitted.

35. Locks The use of tags without locks is not permitted for lockout.
Affected 
Authorized
The use of tags without locks is not permitted for lockout.
All employees working on a piece of equipment must affix locks to the applicable energy isolating devices in accordance with the written procedure
Employees may not work under the protection of another employee’s lock
Locks used for energy control may only have one key
May not be used for any other purposes
Never remove a lock you did not place unless you are following the lock removal procedure

36. Locks CONTINUED Color Purpose
Affected 
Authorized
Color
Purpose 
RED locks indicate that an energy source is locked out by an Eaton authorized employee or contractor who is performing servicing or maintenance activities. Each lock shall be keyed differently. Spare keys will not be maintained. If a key is lost, the lock will be cut from the energy isolation device as outlined in the lock removal section of this program.
Each lock shall be equipped with printed (not handwritten) decals affixed directly to the lock body. The decals shall contain the following information:
Eaton Employees
DANGER – Locked Out – Do Not Remove
Employees name
Employee identification number
Contractor Employees
Company name
Employee name
Phone number

37. Locks CONTINUED
Affected 
Authorized
Front
Back

38. Locks CONTINUED
Affected 
Authorized
Tags or decals used on locks must use DANGER as a signal word

39. Locks CONTINUED Color Purpose
Affected 
Authorized
Color
Purpose
YELLOW locks are used as transition locks. These locks are used between shifts when no one is actively working on a piece of equipment. Transition locks are used for equipment protection rather than people protection. Maintenance and servicing activities may not be performed on the equipment until the yellow locks are replaced with red locks.
Each lock shall be equipped with printed (not handwritten) decals affixed directly to the lock body. The decals shall contain the following information:
DANGER – Locked Out – Do Not Remove
Transition Lock
Transition locks may be keyed-alike. The master key will be maintained by the site’s maintenance leader.

40. Locks CONTINUED Color Purpose
Affected 
Authorized
Color
Purpose
GREEN locks are used to lockout equipment or circuits that are temporarily out of use and not being actively worked on. These locks are used for equipment protection rather than people protection.
Each lock shall be equipped with printed (not handwritten) decals affixed directly to the lock body. The decals shall contain the following information:
Out of Service
Transition locks may be keyed-alike. The master key will be maintained by the site’s maintenance leader.

41. Locks CONTINUED Color Purpose
Affected 
Authorized
Color
Purpose
BLUE locks are used for group lockout in conjunction with a group lockbox.
Each lock shall be equipped with printed (not handwritten) decals affixed directly to the lock body. The decals shall contain the following information in the local language used to conduct business at the site:
DANGER – Locked Out – Do Not Remove
Group Lockout
These locks may be keyed alike. The master key will be maintained by the site’s maintenance leader.

42. Locks CONTINUED Color Purpose
Affected 
Authorized
Color
Purpose
Black locks are not part of LOTO. Black locks are used for permanently locking process valves open or closed until LOTO is needed. When LOTO is needed Red locks will be placed on energy isolation devices. As an example, Epoxy or Powder Coat processes would use this lock.
These locks may be keyed alike. The master key will be maintained in the supervisors/leads office.

43. Lock Removal
Affected 
Authorized
Locks may only be removed by the person who placed the lock
If the owner of the lock cannot be located, a supervisor must:
Attempt to contact the owner of the lock
Inspect equipment and verify safe to operate
Obtain approval from plant manager
Cut the lock
Complete Lock Removal Authorization Form
Review incident with employee immediately upon return to site
The Lock Removal Authorization Form must be completed electronically. Handwritten copies are not permitted.

44. Lock Removal
Affected 
Authorized
Sample lock removal form

45. Contractors
Affected 
Authorized
During the contractor orientation Eaton will issue each contractor employee a sufficient number of RED locks
The project coordinator will supply contractor management with a copy of the applicable equipment-specific lockout procedure
Equipment will be locked out by the project coordinator using RED locks and a lockout hasp in accordance with the applicable equipment-specific lockout procedure. Contractor personnel will then be required to install a RED lock on the appropriate energy isolation device prior to starting a job.
RED locks must be returned to Eaton at the end of the project