Improper lockout procedures are linked to an estimated 10% of industrial incidents, putting workers at risk of serious injuries such as electrocutions, amputations, and crushing injuries.
The Importance of Lockout Procedures
When machinery is being serviced, cleaned, adjusted, or repaired, one of the greatest workplace hazards is the unexpected release of stored energy, which is energy that remains trapped within a machine or system even after the power has been turned off. Lockout and tagout procedures are critical safety measures designed to prevent equipment from being accidentally energized while workers are exposed to dangerous moving parts, electrical systems, or other hazardous energy sources.
What is Lockout/Tagout?
Lockout is the process of isolating and physically securing an energy source to prevent the operation of machinery or equipment. Tagout involves attaching a clearly visible warning tag that identifies who applied the lock, why it was applied, and when the equipment may be returned to service. According to the Canadian Centre for Occupational Health and Safety (CCOHS), lockout is one of the primary methods used to control hazardous energy and prevent unintentional machine start-up.
Together, locks and tags improve communication, reduce the risk of accidental start-up, and help ensure activities such as maintenance, cleaning, repairs, adjustments, inspections, troubleshooting, installation, and equipment commissioning are completed safely.
When to use a Lockout Hasp
When multiple workers are servicing the same equipment, a lockout hasp or lockbox system may be used to allow each worker to apply their own personal lock. The machine cannot be restarted until every lock has been removed. This provides an important additional layer of protection, ensuring that each worker has completed their work and is clear of the equipment before it can be re-energized. It also helps improve communication and awareness among team members throughout the process.
The Safety Risks of Not Locking Out Machines
Failure to properly lock out equipment can have devastating consequences. Workers may be exposed to:
- Electrocution from energized electrical systems
- Crushing injuries from moving machine parts
- Amputations caused by unexpected equipment start-up
- Burns from thermal or chemical energy release
- Injuries caused by stored hydraulic or pneumatic pressure
Requirements for Hazardous Energy Control
While lockout regulations vary by jurisdiction, CSA Z460 is widely recognized as Canada’s benchmark standard for hazardous energy control and lockout programs.
Requirements include:
- Machinery must be rendered inoperative before maintenance, cleaning, repair, or adjustment is performed.
- Energy sources must be isolated and controlled.
- Employers must establish safe work procedures.
- Workers must receive appropriate training and instruction.
- Hazardous energy sources such as electrical, hydraulic, pneumatic, mechanical, thermal, and chemical energy must be controlled before work begins.
Health and safety teams at manufacturing plants should assess their specific operational risks when selecting lockout/tagout solutions, as requirements can vary significantly depending on the machinery, equipment, and application involved.
Fines and Penalties for Non-Compliance
Failure to comply with lockout and hazardous energy control requirements can result in significant consequences for employers, supervisors, and workers. Depending on the jurisdiction, penalties may include:
- Regulatory fines and administrative penalties
- Stop-work orders and enforcement actions
- Prosecution under occupational health and safety legislation
- Potential imprisonment for serious violations or negligence
- Increased workers’ compensation and insurance costs
- Civil liability and reputational damage
Keep your workplace and workers safe
Lockout and tagout procedures are among the most critical safeguards in any workplace that operates machinery or equipment.
Shop our lockout products or contact your Bunzl Safety expert to learn more about building an effective lockout program for your workplace.
