Are you missing this critical step in your lockout procedures?
There’s a reason why lockout tagout citations are considered serious violations. It’s because the injuries that result from lockout incidents can be severe. And often fatal.
In 2023, OSHA found 506 violations for noncompliance with the “control of hazardous energy – procedures shall be developed” requirement. This finding came in fifth on OSHA’s most frequently cited serious violations for general industry.
The penalties for serious violations can reach $16,131 each.
But what is even more costly, is the potential for tragedy to strike if one of those 506 violations were to lead to a workplace incident.
When tragedy strikes: A hypothetical scenario for you to consider
Imagine you work at a large paper mill. And one of your employees was tasked with conducting maintenance on a roller machine. Before getting to work, the employee reviews the written procedures for properly locking out the machine. And follows the steps as they are written.
The employee begins to perform the repairs and positions their body in a gap between the infeed roller gears. When suddenly, the rollers unexpectedly start moving and fatally injure the employee.
How could this happen? You have a lockout tagout program. You have documented procedures. The employee was trained in lockout tagout. What went wrong?
After the investigation had been completed, it was determined that the company failed to update its written lockout procedures after a recent change in the operation was made, which involved the roller equipment.
Because of this, not all energy sources were properly identified and controlled before the employee began the maintenance work.
This is exactly the type of scenario OSHA hopes to prevent when they issue citations for noncompliance with the requirement to have energy control procedures.
Preventing incidents: Key requirements of OSHA’s lockout tagout standard
Listed below are three key elements related to the 506 violations found in the 2023 inspections. As part of the OSHA regulations, employers must:
- Develop, document, implement, and enforce energy control procedures.
- Inspect energy control procedures at least annually.
- Provide effective training for all covered employees.
Going back to the hypothetical situation above, the company failed to protect the worker by not providing the employee with adequate lockout procedures.
And while the requirement is to inspect procedures annually, they must be updated as soon as changes are made to the process or equipment.
Finally, retraining must be provided for all authorized and affected employees whenever there is a change in their job assignments, a change in machines, equipment, or processes that present a new hazard, or when there is a change in the energy control procedures.
Key to remember: Be sure to implement a system to regularly review and update lockout tagout procedures, ensuring that all employees have access to the most current and accurate information.