Lockout Tagout Tryout Explained
What is Lockout Tagout Tryout?
Lockout Tagout Tryout (LOTOTO) is a safety procedure that ensures hazardous machinery and energy sources are properly isolated and cannot be re-energised unexpectedly during maintenance or repair work.
Lockout: Shut down machinery and isolate energy sources
Tagout: Apply a physical lock and tag to warn others and identify the responsible engineer
Tryout: Verify the system is fully de-energised before work begins.
Why is LOTOTO Needed?
Imagine you’re an engineer carrying out maintenance on a machine. You’ve turned off the power and started work, but another member of staff, unaware of ongoing maintenance, enters the room and turns the machine back on. In such cases, you could be seriously injured or killed.
That’s why LOTOTO is so crucial. In fact, LOTOTO is now recognised as best practice for safety management in quarries, oil & gas, heavy manufacturing, food processing plants and more.
How Can LOTOTO Make a Safer Workplace?
Lockout Tagout Training
Training is one of the most important aspects of any LOTOTO programme, as it ensures that all operators are fully equipped to safely isolate and control hazardous energy. Educating staff on what Lockout Tagout Tryout is and how to implement it is the best way to generate buy-in and understanding. Tailoring training sessions to each site’s specific processes and equipment enhances the effectiveness of any LOTOTO programme.
Sessions typically consist of hands-on training, allowing operators to apply equipment themselves. There should also be theoretical training to ensure they understand the dangers associated with the machines they work with.
Lockout Tagout Procedures
Machine-specific energy control procedures are just as important as training. One of the most fundamental requirements of a successful LOTOTO programme is having clear, detailed and written energy control procedures.
One of the most common failings with Lockout Tagout Tryout is a lack of written energy control procedures. Without procedures, workers are left guessing how to isolate energy sources, which increases the risk of errors.
LOTOTO procedures will typically contain:
- The location of the machine
- An image of the energy source
- The type and location of the energy source
- How to switch off the machine
- How to lock out the machine
- What steps are needed to tryout the machine
Internal Auditing
Internal auditing is another important step that employers should implement to ensure that LOTOTO operations are being correctly implemented and carried out.
Employees often cite “accidents have never happened before” or “it will take too long” when referring to LOTOTO procedures, but these are both incorrect and unhealthy workplace practices. Employers must set high safety standards and ensure that employees, including contractors, are educated and follow procedures.
Employees don’t often understand the importance of LOTOTO until something happens or it affects them, so it’s important to act before an accident occurs. It’s better to be proactive and ensure compliance than end up with a fatality or a serious injury. Internal auditing is important for setting standards, but there must be serious consequences for those who don’t follow LOTOTO procedures so staff understand the importance of compliance.
Engagement Materials
Engagement materials are not a replacement for regular training, but they reinforce key LOTOTO messages and processes while engaging operators on the importance of adhering to LOTOTO procedures.
Common engagement materials include booklets and pamphlets that summarise LOTOTO procedures and best practices.
Lockout Tagout Equipment
- Safety Lockout Padlocks: Undoubtedly the cornerstone of any LOTOTO programme, the correct implementation of padlocks is essential. Each padlock is supplied with one key, allowing only the authorised person to remove it.
Every business is unique, and there is rarely a one-size-fits-all solution for LOTOTO. An example of when tailored lockout tagout can be used is introducing a colour-coded padlock system.
Red = Operators
Black = Engineers
Yellow = Contractors
- Ladder Lockout: Ladder lockout is designed to prevent the unauthorised use of ladders or restrict access to sensitive or dangerous areas
- Mobile Lockout Tagout Options: Lockout pouch kits contain a range of essential lockout equipment and are a convenient, portable solution for engineers and operators on the go. Lockout pouch kits either fit onto a belt, or in a van or toolbox, ensuring vital lockout equipment is always within reach
- Custom Lockout Tagout Shadow Boards: Custom shadow boards can be tailored for each machine so each one has a complementary shadow board that accommodates all Lockout Tagout equipment
- General Lockout Tagout Equipment: There are many different Lockout Tagout products that can be used, but each one is used for a specific isolation point. For example, an MCB lockout will be used to isolate an electrical circuit, whereas a valve lockout is used to isolate valves
If employers ensure that all these processes and procedures are followed, they will improve safety standards throughout their workplace, reducing the chance of an injury. Lockout Tagout Tryout is now recognised as best practice for most industries, and following proper procedures is important for creating a safer environment for staff.
Content created in partnership with Spectrum Industrial.
