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Common mistakes to avoid in lockout procedure

Common mistakes to avoid in lockout procedure

One of the main purposes of a lockout tagout is to protect the workplace, employees, and machinery from accidents that may occur during maintenance or repairs. The lockout tagout procedure refers to essential safety protocols taken to secure equipment during maintenance or repair work to prevent accidental activation and harm to employees.

There are various lockouts for different businesses based on use. There is an Adjustable gate valve, Gate valve, No-handle valve lockout, Hubbell plug out, Electrical plug, Battery forklift power, Multi-pole Tie Bar breaker lockout, and more.

However, it is crucial to get suitable lockout/tagout devices from specialist dealers such as MannSupply's Lockout-Tagout to ensure maximum safety.

Here are common mistakes to avoid in the lockout tagout procedure 

  • Inefficient use of tags
  • One of the wrong ways to use the Tag-out is failing to tag the equipment properly. Equipment that has been properly locked and tagged out should guarantee that the machine remains shut down until maintenance is completed. 

    Process of verification includes the following:

    • Verifying that the machine will not start up when the lockout/Tagout device is in place
    • Checking whether machinery and component have been locked
    • Ensuring that stored energy is released
    • Checking whether hazardous energy has been locked out
    • Confirm that suspended parts are lowered to a resting position or blocked to prevent movement.

    In addition, the four types of tags should be included in the Tagout: Danger, warning, caution, and notice. 

  • Lack of proper Equipment-Specific lockout procedures
  • You need to consider that each machine and equipment is unique. Specialized equipment that requires elaborate lockout procedures should be handled with additional attention and care. For this equipment, specific lockout devices for each part and proper identification tags for each employee on the job are a must, without which the maintenance process could prove a challenge. 

  • Failure to identify all energy sources
  • It's crucial to identify and address all potential energy sources that could cause unexpected startup or release of stored energy. If you fail to identify alternative activation or control points, then hazardous energy from the equipment won't be 100% isolated. Common sources include electrical, mechanical, hydraulic, pneumatic, thermal, and gravitational energy. Some of the most overlooked energy sources are separate circuits running to a machine, delivery of energy from an overhead crane or adjacent conveyor, and gravity and kinetic energy.

  • Lack of written procedures: 
  • Failing to document and communicate the LOTO procedures in writing can lead to confusion and errors. Written procedures should include step-by-step instructions, diagrams or illustrations, and any specific requirements for each piece of equipment.

    Without proper procedures being enforced, workers may make very basic—but costly—mistakes like asking their colleagues to perform lockout for them. Marking locks and tags with each person's name or photo can stop good-intentioned workers from using (or removing) someone else's locks or tags. This is also the reason why duplicate keys should never be used.

  • Lack of training
  • Training is the basis of all procedures. Employees entrusted with maintenance or repair jobs must be trained on safety and lockout procedures for systems and equipment under their control. It is a must to hold training for your staff; effective training prevents mistakes, accidents, and injuries.   If you cannot hold a physical session, there are training courses online that can provide value and create awareness for your staff on lockout safety. 

    Lockout/Tagout compliances should be an ongoing process. Normalize continual attention, perhaps once within 24 hours or four times a week. You can significantly enhance the safety of maintenance and repair work, reducing the potential for accidents and injuries. Ready to get a lockout/Tag out product? Start here with

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