ABC Inc.

15 ABC Drive - Buffalo, NY 14210 (716) 555-5551 fax: (716) 555-5550 http://www.abcinc.com Document Title: Lockout/Tagout Procedure Document Number: WI 6.4-2 Prepared By: David S Approved By: David S The purpose of this title page is to have a documented account of any and all revisions to the following procedure. When revising this document the following information will be included as follows; a sequential revision number; the date the revision was made; the review and approval of the Quality Engineer, along with the signature date and a brief synopsis of the change. Each department manager is responsible for determining if this procedure is the latest revision.

Revision Number
0

Date
2/01/2010

Review and Approval with date

2/01/2010

Synopsis
Original Issue

This document is the property of ABC Inc. Any reproduction, publication or distribution of the information contained within this document is prohibited without the express written consent of The Management Representative.

Section No.:

Document No.:

Quality System Manual

Title:

6.4
Sheet:

WI 6.4-2
Rev:

Lockout/Tagout Procedure

2 of 6

Issue Date:

2/1/2010

1.0

PURPOSE: 1.1 This procedure establishes a means to control employee exposure to hazardous energy sources and the accidental starting of machinery or equipment when maintenance, service or cleaning is performed.

2.0

SCOPE: 2.1 This procedure applies to all authorized employees and affected employees who are working on or around the machines or equipment, which have been locked or tagged for service.

3.0

RESPONSIBILITY: 3.1 The Director of Manufacturing is responsible to enforce the lockout/tagout program and insure compliance with this procedure. The authorized employees are required to perform the lockout/tagout in accordance with this procedure. All employees, upon observing a machine or piece of equipment which is locked out to perform servicing or maintenance will not attempt to start, energize or use that machine or equipment.

4.0

PROCEDURE: 4.1 The authorized employee must be aware of and able to identify the type and magnitude of the energy that the machine or equipment utilizes. The authorized employee will understand the hazards of the energy and know the methods to control the four types of energy sources listed: Electrical (the most common form) Hydraulic and pneumatic Fluids and gases Mechanical Chemical Thermal

This document is the property of ABC Inc. Any reproduction, publication or distribution of the information contained within this document is prohibited without the express written consent of The Management Representative.

Section No.:

Document No.:

Quality System Manual

Title:

6.4
Sheet:

WI 6.4-2
Rev:

Lockout/Tagout Procedure

3 of 6

Issue Date:

2/1/2010

4.2

The authorized employee will notify all affected employees that servicing or maintenance is required and that the machine or equipment must be shut down and locked out to perform the servicing or maintenance. If the machine or equipment is operating, it will be shut down by the normal stopping procedure (such as depressing the stop button, turning the on/off switch to off, closing a valve or other) as noted in the de-energization procedure. De-activate all energy isolating devices so that the machine or equipment is cut off from all energy sources. This includes circuit breakers, power cords, valves (hydraulic, pneumatic, fluid or gas) or any mechanical device used to operate or energize the machine or equipment. Authorized employees who perform any maintenance where the energy source has been locked out will use a tag along with a lockout device and an assigned lock. The tag will list the authorized employee who issued it along with the date it was issued. If a lock can not be used, another method to isolate the energy source equivalent to the level of safety provided by a lock must be utilized, such as the following: 4.5.1 4.5.2 4.5.3 4.5.4 The use of a nylon cable tie to attach a tag. The removal of an isolating circuit element. The blocking of a controlling switch. The opening of an extra disconnecting device.

4.3

4.4

4.5

4.6

Authorized employees who perform maintenance will utilize the following guidelines to ensure the machine or equipment has been properly deenergized: 4.6.1 A qualified person will test the electrical circuit elements and parts of equipment to which employees will be exposed and will verify that the circuit elements and equipment parts are de-energized. The test will also determine if any energized condition exists as a result of inadvertently induced voltage or unrelated voltage back feed even though specific parts of the circuit have been de-energized and presumed safe.

This document is the property of ABC Inc. Any reproduction, publication or distribution of the information contained within this document is prohibited without the express written consent of The Management Representative.

Section No.:

Document No.:

Quality System Manual

Title:

6.4
Sheet:

WI 6.4-2
Rev:

Lockout/Tagout Procedure

4 of 6

Issue Date:

2/1/2010

4.6.2

Stored or residual energy (such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems and air, gas, steam or water pressure, etc.) must be dissipated or restrained by methods such as grounding, repositioning, blocking, bleeding down, etc. Ensure that the equipment is disconnected from the energy source(s) by first checking that no personnel are exposed, then verify the isolation of the equipment by operating the push button or other normal operating control(s) or by testing to make certain the equipment will not operate.

4.6.3

Note: Return operating control(s) to neutral or off position after verifying the isolation of the equipment. 4.7 4.8 The machine or equipment is now regarded as being properly locked out and safe to perform any maintenance or service needed. In situations where the lockout/tagout device must be temporarily removed and the machine or equipment is to be energized in order to test or position the machine, the following steps should be taken: 4.8.1 4.8.2 Check to be sure all affected employees are safely clear of the area. Clear the machine or equipment of all tools and materials, remove the lockout/tagout device(s) and energize the machine or equipment. Perform the testing or positioning necessary, de-energize the machine or equipment and reapply the lockout/tagout device per steps 4.2 through 4.11 above.

4.9

In the event of a shift/personnel change, the on-coming authorized person will check out the machine or equipment and ensure proper lockout procedures have been followed. The authorized person will then apply their personal lock to the lockout device once the procedures have been verified. When the servicing or maintenance of the machine or equipment is performed by more than one individual a multiple lock scissor clamp must be used so that each person performing the work can put his or her lock on the equipment or machine.

4.10

This document is the property of ABC Inc. Any reproduction, publication or distribution of the information contained within this document is prohibited without the express written consent of The Management Representative.

Section No.:

Document No.:

Quality System Manual

Title:

6.4
Sheet:

WI 6.4-2
Rev:

Lockout/Tagout Procedure

5 of 6

Issue Date:

2/1/2010

4.11

An employee will never remove another persons lockout without management approval and/or supervision. In the event of an employee forgetting to remove a lockout/tagout device and going home, the following steps should be taken: 4.11.1 The company management will make every effort to get in touch with the authorized employee. 4.11.2 If the employee cannot be contacted, another authorized employee and the supervisor will check out the equipment and make sure there is no danger in removing the lock. 4.11.3 A supervisor will remove the device and the absent authorized employee will be notified that his/her lock was removed before they return to work.

4.12

The following steps will apply for all outside contractors performing any maintenance or service on machines and equipment. 4.12.1 Outside contractors will use the lockout/tagout procedure enforced by their own company. 4.12.2 In the event that an outside contractor does not have procedures regarding control of hazardous energy, they may use our procedures. 4.12.3 The outside contractor will provide us a copy or description of their procedure so that we can ensure that our employees understand and comply with the restrictions and prohibitions of the outside contractors lockout procedures.

4.13

When the servicing or maintenance is completed and the machine is ready to return to normal operating condition, check the machine or equipment and the immediate surrounding area to ensure that nonessential items have been removed and that all components have been reinstalled and are operationally intact. Check to be sure all affected employees are safely clear of the area, verify that the controls are in the neutral or off position, remove the lockout devices and reenergize the machine or equipment.

4.14

This document is the property of ABC Inc. Any reproduction, publication or distribution of the information contained within this document is prohibited without the express written consent of The Management Representative.

Section No.:

Document No.:

Quality System Manual

Title:

6.4
Sheet:

WI 6.4-2
Rev:

Lockout/Tagout Procedure

6 of 6

Issue Date:

2/1/2010

4.15 4.16

Note: The removal of some forms of blocking may require re-energization of the machine before safe removal. Notify all affected employees that the servicing or maintenance is completed and the machine or equipment is ready for use.

This document is the property of ABC Inc. Any reproduction, publication or distribution of the information contained within this document is prohibited without the express written consent of The Management Representative.