Case study - implementation of the LOTO system in a production plant

Since the system was implemented, we have not recorded
a single accident!

This is how Ms. Justyna summarizes a year with the LOTO system - SH&E Specialist
at Mondi Bags Mielec

One year after implementing the LOTO system - Mondi tells its story:

• WHY they decided to implement the LOTO system
• WHAT THEY GAINED, what results and benefits the implementation of the LOTO system brought them 
• How they EFFECTIVELY manage the elimination of accidents at the production plant

And a bonus from us -  what the proper implementation of the LOCKOUT/TAGOUT system should look like. 

Can LOTO be just instructions on paper? Complicated procedures and dusty equipment? Or is it a step forward in building a safety culture at the plant? 

A plant that invests in safety gains twice – it not only protects the health and lives of employees, but also increases the efficiency and stability of production processes by eliminating the risk of costly downtime and accidents.

One of the 9 main working principles at Mondi concerns machine isolation, which – as Ms. Justyna emphasizes – would be impossible to achieve without the LOTO system.

Watch a short video straight from the heart of production at Mondi Bags!  See what LOTO implementation looks like in practice. Take a look behind the scenes of safety and hear the opinions of Justyna Moździoch, SH&E Specialist, and Marek Krupa, Plant Manager.

https://www.youtube.com/watch?v=QdiX5LOJnpo

What did the implementation of the LOCKOT/TAGOUT system consist of?

Stage 1: ZERO Audit

A meeting and discussions at the plant during which a 4safety expert analyzes the plant's specifics and develops an individual implementation plan.

Stage 2: Detailed audit

A visit to the plant involving the detailed preparation of a list of devices subject to the LOCKOUT/TAGOUT system. 
• Reviewing and listing hazardous energy isolation points • listing switches/valves and their locations.

Stage 3: Development of workstation instructions

At this stage, the implementer prepares machine lockout instructions for each device. These instructions contain the steps that must be taken to isolate energy sources and verify whether the so-called zero state has been achieved.

Stage 4: Equipment selection and marking of LOTO points

Selecting the appropriate equipment, storage method, and marking energy isolation points. Choosing lockout devices and padlocks, as well as boards adapted to the specific requirements of the machines and devices located at the plant.

Stage 5: Employee training + practical workshops

The final step is to conduct a series of training sessions for employees. The purpose is to familiarize staff with LOTO procedures, but also to dispel doubts and provide education about the hazards associated with improper machine safeguarding. 

See the board individually prepared for Mondi - thanks to it, employees have easy and convenient access to LOTO lockout devices and instructions.

What did Mondi gain thanks to implementing the LOTO system?

Elimination of accidents

Since the LOTO system was implemented at the plant, no accident related to hazardous energy has been recorded.

Clear procedures

Short and understandable instructions made it so that every person involved in the production process knows how to safely shut down and lock out machines.

Less downtime

Downtime resulting from hazardous energy-related situations has been significantly reduced.

Improved efficiency

Maintenance and repair processes are now faster and safer, which affects production continuity and plant efficiency.

Dedicated equipment

Quick access to the right equipment allows for immediate action when machine isolation is needed.

Tailored training

Workshops and training build greater team awareness and competence in the field of safety.

Why is it worth implementing the LOTO system with 4safety ?

It IS WORTH IT because you choose not only safety – you choose years of experience, hundreds of successful implementations, and the certainty that every detail will be refined with your plant in mind.

With our experts, you have a guarantee that LOTO implementation will not be just a set of procedures, but real support for your team. Thanks to the knowledge they have developed both in Poland and abroad, they know how to adapt solutions to the specifics of even the most demanding production environments.

We place a strong emphasis on training! Even the best-implemented system will eventually stop being used without proper training. 

It is important that employees understand the purpose and importance of using the system. That they learn how to efficiently select and use the equipment. For this, practical training and periodic training are essential.

Thanks to them, consolidated knowledge turns into habits. 

As a result – less downtime, and above all – peace of mind, because you know you are doing everything to protect your employees and maintain production stability.

In the photo: Grzegorz Kwaśnik, Product Manager at 4safety - LOTO system implementation specialist at Mondi Bags . 

Do you want to increase safety and work efficiency at your plant?

Fill out this short form and schedule a free ZERO audit with an expert. 

At such a meeting, you will learn what the implementation will look like, what exactly you will gain thanks to the LOTO system, and you will discuss the individual needs and challenges of your plant in order to adapt the solutions to the specifics of your production. 

Don't wait, don't implement LOTO after an incident! 

What our Clients say about us:

Cooperation with 4safety contributed to the implementation of the LOTO system used in daily work, which increases the level of safety for people and the machinery park. Linde Gaz Polska 4safety provided comprehensive support for the implementation of the LOCKOUT/TAGOUT system in the field of creating full documentation, selecting equipment, and conducting training. Westwing ELC Training conducted by Marcin Sobczyk from 4safety improved our awareness and knowledge in the use of the LOTO system. Robert Bosch

We work only with the best equipment from the BRADY brand.  From solid padlocks and lockout devices to durable markings. Equipment that we know will not let you down even in the most demanding conditions. 

When choosing an implementation company, it is worth paying attention to what equipment it works with. Safety and the effectiveness of the entire LOTO system also depend on it.

Learn more about the LOCKOUT/TAGOUT system

Lockout/Tagout - what is it and why is it worth implementing LOTO?

In this post you will find everything you need to know before implementing the LOTO system in a nutshell!

Read

Why is it worth implementing the LOTO system with Marcin from 4safety?

How to implement the Lockout/Tagout system so that it constitutes an integral and valuable improvement to workplace safety standards?

Read

The importance of the padlock in the LOTO system

Are you sure you use padlocks correctly and that you make use of all their properties? Learn the meaning of the most important features of padlocks intended for the LOTO system.

Read