LOTO lockouts

LOTO lockouts (Lock Out - Tag Out)  a set of tools used in industry and other environments to safely isolate or lock machines, devices, and energy systems against unauthorized or accidental start-up or activation. 

The abbreviation "LOTO" refers to the two main steps of the procedure: "Lock Out" (lockout) and "Tag Out" (tagging). LOTO lockouts are used to ensure worker safety and avoid accidents related to hazardous energy.

LOTO lockouts are particularly important during maintenance work, repairs, tool or material changes, as well as in emergency situations. The use of LOTO lockouts helps minimize the risk of accidents and ensure safety in the workplace, contributing to the protection of workers and property from potential hazards

Why should LOTO lockouts be used when working on machines and equipment?

Worker protection: these lockouts allow workers to shut down and secure machines and equipment against accidental start-up, protecting their lives and health.

Minimizing the risk of accidents: LOTO lockouts eliminate the risk of uncontrolled starting or activation of machines and equipment, which is a frequent cause of accidents. Fewer accidents and lower injury-related costs.

Maintaining machine integrity: thanks to LOTO lockouts, accidental damage to machines and equipment can be avoided, resulting in longer equipment lifespan and reduced downtime related to failures.

Compliance with regulations: in many jurisdictions and industries, the use of LOTO lockouts is mandatory and constitutes compliance with legal regulations. Many contractors, especially from the USA, require the use of the LOTO system from their business partners.

Shorter downtime and higher productivity: a properly implemented LOTO program (clear marking of energy sources, understandable procedures may significantly streamline and shorten work.

‍Reduction of indirect costs: accidents can have a major impact on work planning and employee productivity. Unexpected start-up of a device can damage it and increase the existing costs of repairing or replacing such a device.‍

Increasing work comfort: confidence that the machine is properly secured increases the sense of safety, work comfort, and employee productivity.

When are LOTO lockouts necessary?

LOTO lockouts are essential in many situations, including:

Maintenance work: when performing maintenance or repair work on machines or equipment that require the power supply to be disconnected.

Cleaning and maintenance: during cleaning, cleaning work, or maintenance where it is necessary to switch off machines and prevent them from being accidentally turned on.

Changing tools or materials: at the moment when a change of tools, materials, or settings on machines is required.

Emergency situations: in the event of emergency situations where immediate disconnection of the power supply and securing is necessary.

Protection against unauthorized access: securing mechanisms and switches against interference by unauthorized persons. 

Types of locks in the Lockout Tagout (LOTO) system:

• Electrical equipment locks
• Cable locks
• Hose and valve locks
• Hasp locks
• Group lockout boxes and permit control stations
• Lockout padlocks:

These padlocks are usually used to secure control elements such as buttons, levers, or valves.

When selecting appropriate LOTO (Lock Out - Tag Out) locks for machines and equipment, it is worth paying attention to several important factors. This is a process best carried out in cooperation with an experienced safety auditor, especially in the case of production lines. 

What is worth paying attention to when choosing LOCKOUT/TAGOUT locks:

Identifying the energy source: the first step is to thoroughly understand which energy sources powering the machine or device need to be locked out. 

Inventory of machines and equipment: precisely identifying all machines and equipment that require LOTO locks. It is worth creating a list so that nothing is overlooked.

Types of locks: selecting the appropriate types of locks and their quantities that will best fit specific machines and equipment.

Quality of lockouts: it is important to choose the highest quality lockouts so that you can be sure they are difficult to bypass and remove, and resistant to the conditions in your facility. 

Adaptation to the machine: making sure that LOTO lockouts can be easily installed and adapted to a specific machine or device. Choosing lockouts that fit different types of equipment.

Optimizing the number of lockouts: in the case of production lines, an experienced auditor will help optimize the number of lockouts and adapt them to specific needs, while minimizing the time needed to lock and unlock machines and reducing your expenses by selecting the right quantity and type of lockouts so that they fit several devices. 

Hazardous types of energy where LOTO lockouts are an effective control system:

• Electrical energy

• Mechanical energy

• Pneumatic energy

• Hydraulic energy

• Chemical substances in liquid and gaseous form

• Thermal energy

• Hot surfaces and substances

• Gravitational energy

• Energy from potentially falling elements located at height,

• stored energy of another kind,

• Energy from a flywheel stopped in motion or energy from residual current requiring discharge.

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It should be remembered that industrial devices usually use at least two types of energy.

What the ideal Lockout/Tagout lockout should be:

• Easy to use and apply, remove and install.
• Convenient to carry, lightweight.
• Effective in locking out various energy control point configurations.
• Resistant to diverse environmental conditions.
• As universal as possible, used to lock out many electrical energy control points or valves.
• It should have space for a padlock/multiple padlocks for complete lockout.

LOTO lockout sets

Lockout sets are a convenient-to-use collection of appropriately selected types of lockouts.  It is a quick way to start your journey with the LOTO system and thus increase safety and work efficiency. 

We will create the right LOTO lockout set for you, tailored to your needs. 

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In summary, choosing the right LOTO lockouts is crucial to ensuring the safety of employees and machines. It is worth paying attention to all the above aspects and consulting an experienced auditor to ensure optimal and safe solutions for locking out machines and equipment. Remember that even the best equipment will not replace employee awareness and appropriate procedures. Therefore, it is important that everyone involved knows the procedures accompanying energy isolation, knows exactly how and when to use lockouts, and how to handle them. Training employees in the use of LOTO lockouts and educating them about safety procedures is essential. Employees must know when and in what situations they must use lockouts, how to mark them and secure them, e.g. with an appropriate padlock. 

Choose the right LOTO lockouts from our offer. We have a wide selection of lockouts for the most demanding conditions.  If you need advice, schedule a consultation with our LOTO auditor, who will help assess the needs in your organization and select the appropriate lockouts.