2. Top 10 Most Frequently Cited Standards
for Fiscal 2013 (Oct. 1, 2012 to Sept. 30, 2013)
● The following is a list of the top 10 most
frequently cited standards* following inspections
of worksites by federal OSHA. OSHApublishes
this list to alert employers about these commonly
cited standards so they can take steps to find and
fix recognized hazards addressed in these and
other standards before OSHA shows up. Far too
many preventable injuries and illnesses occur in
7. Key Definitions
Affected employee: An employee who operates or
uses a machine or equipment on which servicing or
maintenance is being performed under lockout or
tagout,or who works in an area where lockout tagout
Authorized employee: A person who locks out or
tags out machines or equipment to do serve or
maintenance work on them. An affected employee
becomes an authorized employee when his or her
duties include performing covered service or
Other Employee: An employee whose work
operations are or may be in an area where energy
control procedures may be utilized.
8. Key Definitions cont.
Energy isolating device:
A mechanical device that physically
prevents the transmission or release of
energy, including but not limited to the
● A manually operated electrical circuit
● A disconnect switch.
● A line valve.
● A block and any similar device used to block
or isolate energy.
● Push buttons, selector switches, and other
control circuit type devices are not energy
9. Key Definitions cont.
Any source of electrical, mechanical,
hydraulic, pneumatic, chemical, thermal, gravity, or
Energized: Connected to an energy source or
containing residual or stored energy.
Tagout: The placement of a tagout device on an energy
isolation device, in accordance with an established
procedure, to indicate that the energy isolating device and
the equipment being controlled may not be operated until
the tagout device is removed.
A prominent warning device, such as a tag and a means of
attachment, that can be securely fastened to an energy
10. When does the standard apply?
The standard applies to repair work (servicing
and or maintenance) to powered machines or
The standard must be followed during work that
is done during normal production operations if :
– “An employee is required to remove or bypass a guard or
other safety device.”
– “An employee is required to place any part of his or her
body into a machine’s point of operation or a danger zone
associated with a machine’s operating cycle.”
The standard does not apply to cord and plug connected
electric equipment when unplugging the equipment controls
the hazards and the plug is under the exclusive control of the
employee who is doing the service or maintenance work.
11. Energy control program
The standard requires employers to have and energy
control program that include:
● Energy control procedures.
● Employee training.
● Periodic inspections.
Energy control procedures
Documented energy control (lockout/tagout) procedures
● Outline the intended use of the procedure.
● Indicate specific steps to lock out or tag out the machine or
● Include rules and authorizations for using the procedure.
● Have an explanation of how compliance will be enforced.
12. Energy control procedures cont.
The employer must have multiple
procedures when various types of
machines or equipment in the
facility would need different
lockout tagout procedures. Each
lock out tag out procedure needs
to identify the machines or
equipment to which it applies.
14. Six steps for applying lockout/tagout
1. Prepare for shutdown.
● Understand the equipment.
● Turn off or power down according to procedures.
15. 3. Isolating equipment.
● Locate all disconnect switches, circuit breakers valves.
4. Applying locks and tags.
● Lockout devices must hold switches/valves in the “safe” or
Six steps for applying lockout/tagout
16. Six steps for applying lockout/tagout
5. Releasing stored energy.
Bleed off pressure.
Blocking elevated parts in place.
Let equipment cool.
17. Six steps for applying lockout/tagout
This last, crucial step ensures that the lockout
tagout procedure has successfully isolated the
machine or equipment from its energy
sources the machine is in a “zero energy
To do this the authorized employee may
operate the machine’s controls to verify the
equipment is isolated then return the controls
to their “Off” positions. The verification
process could also include reading pressure
or temperature gauges and using test
19. Release from lockout/tagout
When repair or maintenance work is
1. Check the machine.
● Replace guards, remove tools, blocking devices.
2. Check for employees.
3. Remove lockout tagout devices.
● Notify all affected employees that work is
20. Use of tag out alone
● In rare cases, (older machines) an energy source cannot be locked
out. In these situations a tagout procedure needs to be used.
Please be aware of the limitations of tags when a tagout system is
● Tags are warning devices. They do not provide the same physical
control as a lock.
Tags must not be bypassed or ignored.
● Tags can only be removed by authorized employee responsible for
Tags must be legible.
Tags must be understandable by all employees in the area.
Tags must hold up under the conditions of use.
Tags may evoke a false sense of security.
Additional safety measures may include: Removing a valve
handle, blocking a controlling switch, removing and isolating a
21. Maintaining lockout/tagout during shift
change or personnel changes
If service or repair work needs to continue during the next shift.
And , there are situations where a mechanic is called away to
another job and another repairman arrives to continue the work.
In both of these cases, the lockout tagout condition needs
continue even though the people working on the project have
Remember that the employee who applied the LOTO device is the
employee who must remove it. An authorized employee is not
allowed to merely give the key to his lockout device to his
It is also a requirement that the authorized employee who is
working on the equipment is the same person who applied the
lock and tag. The authorized employee who is leaving cannot
merely leave his or her lock in place and allow the on-coming
authorized employee to work on the equipment with out applying
his own lock and tag.
22. Removal of lockout/tagout when the
authorized employee is not available
There are situations where machines or equipment have
been locked out by personnel who then become
unavailable, (Gone home for the day) or not available for
any number of reasons.
This calls for alternate procedures to safely remove the
lockout tagout devices. Your employer needs to have
specific documented procedures as part of the company’s
energy control program in order to have these devices
removed. Employees who are involved in carrying out
these procedures need to be trained to follow them carefully.
● The employer must verify that the authorized employee
who applied the device is not at the facility.
● Reasonable efforts to contact the authorized employee
must be made to let him know that his or her lock will
● Steps must be made to contact the employee to notify
him/her of the removal before they return to the facility.