1. “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.

2. 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

3. 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.

4. 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

5. 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”

6. “??? 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

7. 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?

8. 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

9. 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”

10. 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

11. 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”

12. 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

13. 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

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

15. 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