Lockout

Information

Document No.
Audit Title
Client / Site
Conducted on
Prepared by
Location
Personnel

Procedure

Is there a written lockout program developed and implemented at your facility that specifies the procedures to control energy during servicing and maintenance of machines and equipment?
Does the written lockout program specify the use of locks and lockout devices on machines and equipment to prevent unexpected energization, start-up or release of stored energy and protect team members from injuries?
Does the written lockout program consist of: a) energy control procedures b) team member training requirements c) periodic documented observations to confirm team member compliance with the procedures

Devices and Equipment

Does all equipment repaired or replaced after January 20, 1990 have an energy isolating device which allos a lock to be securely attached to the equipment to isolate energy?
Are all lockout devices comprised of a key type lock which can be used to hold an energy isolating device in the safe position and prevent release of energy to the machine or equipment?
Are lockout devices and hardware provided to team members for isolating, securing or blocking of machines or equipment from energy sources?
Are all locks: * Singularly identified * The only device(s) utilized to control energy * Not utilized for any other purposes
Do all lockout devices meet the following requirements: * Durable - capable of withstanding the work environment for maximum periods of time * Standardized - lockout devices at the facility are standardized in at least one of the following: color, shape or size * Substantial - lockout devices are substantial enough to prevent removal unless excessive force or metal cutting tools are used * Identifiable - lockout devices provide information identifying the team member that applied the device

Inspections

Is the periodic inspection completed by an authorized team member other than the team member utilizing the procedure being inspected?
Is a periodic inspection of the production energy control and lockout procedures conducted at least once annually to confirm the effectiveness and compliance of the procedures? If yes, is there documentation available for review? Documentation must include: * Identification of the machine or equipment * Date of inspection * Team members included in the inspection * Person performing inspection
Does the periodic inspection include correction of identified deviations and noncompliance items?
Does the periodic inspection of the lockout procedures include a review of team member responsibilities when completing the process to control energy?
Are all periodic inspections verified by providing the following information: * Machine or equipment covered by the lockout procedure * Date of inspection * Name of team members included in the inspection * Name of person performing the inspection
Is there sufficient working space around electrical equipment for safe operation and maintenance? * The distance around equipment is at least 3 feet * Required space around equipment is not used for storage * The width of the working space must be the width of the equipment or 30 inches, whichever is greater * Electrical equipment with doors must have enough working space to allow the door to be opened at a 90 degree angle

Training

Are all authorized team members trained to recognize hazardous energy sources, types and magnitudes of energy in the workplace and methods and means to isolate and control energy?
Are all team members trained in the purpose and utilization of lockout procedures?
Does retraining of team members occur when there is a: * Change in job assignments * Change in machines, equipment or processes * New hazard involved in the process * Change in energy control
Is retraining conducted when a periodic inspectin show inadequacies in the understanding and use of energy control and lockout procedures?
Is retraining documented and records maintained including the team members name and date of training?
Are the training and retraining records up-to-date and available for review upon request?

Procedures

Are lockout procedures only performed by authorized team members performing the servicing or maintenance?
Are team members affected by the energy control or lockout notified by the employer or authorized team member about the application and removal of energy control and lockout devices? Notification must be provided before controls are applied and after removal.
Does the lockout procedure address the following elements and actions in the following sequence: * Preparation for Shutdown - before controlling energy from machines or equipment, the team member has knowledge of the type and magnitude of energy, hazards of energy and means to control energy * Machine or Equipment Shutdown - Machines or equipment are shutdown using the established procedures and energy control devices * Machine or Equipment Isolation - All isolating devices required to control the energy effectively must be physically located and properly operated to isolate the machine or equipment
Are lockout devices placed on each energy isolating device by authorized team members only?
Are lockout devices applied to ensure the energy isolating device is held in the safe or off position?
After the lockout device is applied to isolate the energy, is all stored and residual energy relieved, disconnected, restrained and rendered safe?
If the potential for re-accumulation of stored energy to a hazardous level exist, is the continuous verification of isolation performed until completion of servicing or maintenance is conducted?
Do authorized team members verify isolation of energy on machines or equipment has been accomplished before starting work?
Before lockout devices are removed and energy restored, are the proper procedures followed and tasks performed by authorized team members to ensure the following: * Machine or Equipment - the work area is inspected to confirm nonessential items are removed and the machine or equipment components are operationally intact * Team Members - the work area is assessed to ensure all individuals are safely positioned or removed from the hazardous area * Team members are notified when the isolation device is removed and before the machine or equipment is started
Is the lockout devices only removed by the authorized team member that applied the energy isolating device?
Is there a specific procedure when the team member that applied the lockout device is unavailable to remove the device? If yes, does the procedure include: * Verification by the employer that the authorized team member that applied the device is not at the facility * All reasonable efforts have been made to contact the authorized team member and inform them that their lockout device has been removed * Ensure the authorized team member understands that their energy isolating device has been removed before they resume work at the facility
Is there a procedure developed when the lockout needs to be temporarily removed to test or position the machine, equipment or component? If yes, does it include the following: * Clear the machine or equipment of tools and materials * Remove the team members from the machine or equipment * Remove the lockout device * Energize and proceed with testing or positioning * Deenergize all systems and reapply energy control measures to continue maintenance or service
Does the written lockout procedure outline the scope, purpose, authorization, rules and techniques for control of hazardous energy?
Do the written lockout procedures include means to enforce compliance such as: * Specific statement detailing the intended use of the procedure * Procedural steps required to shut down, isolate, block and secure machines or equipment to control hazardous equipment * Specific procedural steps detailing the placement, removal and transfer of lockout devices and responsibilities of person's owning the lockout devices * Specific requirements for testing the locked out machine or equipment to verify the effectiveness of the lockout performed

Contractors

Contractors are informed of the onsite production energy control and lockout procedures at the facility?
Is it confirmed that all contractors understand and comply with the lockout program before, during and while completing work onsite?

Group Energy Control Procedures

Are group lockout procedures included in the written production energy control and lockout program?
Is an authorized team member assigned primary responsibility for a set number of team members working under the protection of a group lockout device?
Does the authorized team member assess the exposure status of the protected group members with regard to the lockout of the machine or equipment?
When more than one group is assigned to an overall job associated lockout, is there an authorized team member designated to coordinate affected work forces and ensure continuity of protection?
Does each authorized team member involved in the group lockout apply their personal lockout device to the group lockout device, group lock box or other group energy control mechanism at the start of work?
Does each team member remove their personal lock from the group lockout when they stop working on the machine or equipment?
Are there specific procedures included in the production energy control and lockout procedures to address shift and personnel changes to ensure the continuity of lockout protection is maintained for the necessary time period (specifically when the lockout covers more than one shift)?

ANSI Z244-2003

Are bleed-off valves for stored pneumatic or fluid energy readily available, labeled and confirmed?
Are all residual energy sources marked appropriately?
Are energy blocking devices readily available for stored kinetic energy and tested?
Are blocking devices painted red?
Do hazardous motion control devices utilize a lock, hasp, flap or similar exclusive control device?