lockout – tagout procedures - training · pdf filesafety productions“lockout...

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F A C I L I T A T O R G U I D E

SAFETY PRODUCTIONS “Lockout – Tagout Procedures”, Facilitator Guide Page 1 of 14

Table of Contents

Introduction …………………………………………………….………..................................……2

Where to Begin ………………………………………………….……………………….......………..3

Tips for Conducting an Effective Training Session ……………….....……………………………...4

Recommended Syllabus ……………………………………......………………………………….....5

The PowerPoint® Presentation ………………………......……………………………………………6

Quiz ……………………………………………………..........…………………………………………9

Quiz Answers ……………………………………….......…………………………………………….11

Copyright 2005-2006, Safety Productions

Safety Productions4730 Venetian Drive, SEGrand Rapids, MI USA 49546Tel: (616) 450-5753Fax: (616) 949-3113

Printed in the USA. Content subject to change without notice.

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means,electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from Safety Productions.

Microsoft and Microsoft PowerPoint are registered trademarks of the Microsoft Corporation.

All other trademarks, service marks, products and services are trademarks or registered trademarks of their respective holders.


IntroductionEnergy plays a valuable role in all of our lives every single day. It is such an integral part of our lives, both onand off the job that we can tend to under estimate or not respect its risks and potential hazards if not properlycontrolled.

A person would not work at a place of business where they spin a wheel-of-chance each day to see if they getinjured. Yet millions of workers inspecting, adjusting, servicing or maintaining equipment and machinery take thesame risk every day when they elect not to isolate energy sources before placing themselves in harms way.

According to government statistics, it is estimated that over 100 workers are seriously injured every day due tofailure to properly Lockout - Tagout equipment. Workers can be seriously injured or killed by electrical shock,high pressured liquid sprays, or falling and moving parts. They can lose fingers, hands, arms; suffer severe burnsor crushing injuries.

An injury due the accidental release of stored injury can occur in a second, but affect you the rest of your life.Lockout - Tagout related injuries are not an acceptable fact of the workplace. These types of injuries are 100percent preventable when proper Lockout - Tagout measures are taken.

The objective of this program is to create awareness and respect for the hazards associated with the accidentalrelease of stored energy and motivate your employees to utilize best practices and procedures to properly lockoutand tagout equipment to ensure their safety.

This program covers:• The purpose of Lockout Tagout procedures• The hazards associated with the accidental release of energy• The different types of energy found in the work environment• The importance of planning and hazard assessment• Proper communication to affected workers• Lockout Tagout procedures• Safe work practices during Lockout Tagout procedures• Start up procedures• Special circumstance you may encounter

The Facilitator's Guide provides many helpful suggestions and recommendations for conducting an effective andsuccessful training session. It contains a recommended syllabus, discussion topics, site specific customizationtips and a quiz to document and measure your workers' understanding of the hazards and measures they can taketo ensure the safe and proper de-energization of equipment and machinery before placing themselves in harmsway.


Where to BeginIt is strongly recommend that you become familiar with all the material contained in the training package beforeconducting the training. Schedule 45 minutes to an hour to watch the videotape, review the Power Pointpresentation, and to read this Facilitator's Guide.

When watching the videotape, it is a good idea to have pen and paper available to make notes and write down anyideas that come to mind. Watch the program to get a basic understanding of the content, its tone and approach.Note any points or examples presented in the video that you can reference to specific incidents or situations atyour site. Write a brief introduction for the video. A sample one is provided in this Guide.

Review the PowerPoint® presentation. Write down the comments or discussions you would like to make for eachspecific slide. Discussion points are provided in the PowerPoint® section of this Guide. You may also wish tocustomize the PowerPoint® presentation with your own pictures, additional slides or text changes. Audienceparticipation is an important element in successful adult learning.

Determine how and when the training will occur. Will you train the entire facility or department staff at one timeor will you conduct multiple training sessions? How will you coordinate make up sessions for associates who missthe training? Will the training be a part of a regularly schedule meeting or will it be a standalone session? Howmany people will your presentation equipment accommodate? Fifteen people cannot effectively view a 12 inchmonitor at one time. Consider the different variables for your site and establish when and where the training willoccur. Suggestions are:

Training for newly hired employeesWhen changes occur in the work site or job assignmentRefresher training for your team (i.e. 12 month intervals)

Develop a lesson plan based upon the time allotted for training. A sample one for a 45 minute training session isprovided in this guide. This schedule can be modified to meet your specific time requirements.

Communicate to your employees the date, time and place of the training. A small reminder poster or sign placedin the break room, by the time clock, or other common area can provide an indirect positive reinforcement ofsafety at your site

A successful training presentation requires preparation and planning. Allow yourself enough time to getorganized.


Tips for Conducting an Effective Training SessionHow you present the material and the environment you present it in can have a great impact on the learning andsuccess of your training. The following are some recommended guidelines and suggestions that can help ensureyour success.

Be prepared for the training. Make sure you have all the supplies and equipment necessary. Check to make sureall equipment is functioning properly and that all media is cued and ready to play. Technical malfunctions cangreatly impact the training in a negative way. Bright lights and glare can greatly reduce the effectiveness of eventhe best produced media.

Select a location conducive to learning. Avoid areas of high traffic and interruption. Make sure the room cancomfortably accommodate all attendees. Can everyone easily see and hear the instructor and all visual aids usedin the training.

Organize your training time efficiently. In today's busy work environment, respect your employees' time. Developa lesson plan and stick to it. You will come across as organized and ensure you have covered the content youwanted to.

Be positive and enthusiastic about the material you are presenting. If you are not excited about it your audiencenever will be.

Let the audience know the objectives and the goals of the training. Adults want to know what is in it for them. Isthe purpose to reduce injuries, communicate new skills and techniques, or address a specific issue? Let themknow what is expected and what the benefit is.

Know your audience. Is this new information? What is their comprehension level and previous experiences? Youcan keep the training interesting and beneficial by making the content specific to the associates and encouragingpositive participation. Passive listening is the least effective form of communication.

Schedule time for and encourage questions from your audience. Their questions can provide instant feedback onhow your presentation is being received. Don't get defensive when taking questions. Provide direct answers tothe questions. If you don't have the answer, admit it, and then let them know you will get the answer and getback to them as soon as possible.

Encourage participation, feedback and questions on how they can improve safety at your site or work safer toprevent accidents. Everyone learns when there is a team commitment to injury prevention.


Recommended Syllabus(45 Minutes)

3 min. Welcome the group and open the training session. Review the training session's agenda(video, PowerPoint® and discussion, quiz). Discuss the purpose and objective of thetraining.

15 min. Introduce and show the video Lockout - Tagout Procedures

Sample Introduction: Safety is an important part of everything we do at (name of site).Safety is everyone's responsibility. Lockout - Tagout is a serious issue. An injury causedby the accidental release of stored energy can happen in a second, but affect you the restof your life. Workers injured on the job from the accidental release of stored energy losean average of 24 work days per incident. The video we are about to see was produced tohelp us learn that injuries caused by the accident release of stored energy can beprevented if we understand how they occur and what to do to work safely. It addressesspecific situations we encounter regularly and provides recommendations to preventincidents and ensure our safety. Let's watch the program.

15 min. PowerPoint® presentation, discussion, and questions

12 min. Quiz and review


The PowerPoint® PresentationThe Power Point presentation is provided to reinforce key points made in the video, and to facilitate and enhanceclass room discussion and participation. You may customize the presentation by adding or deleting slides,changing the text or inserting your own pictures.

Slide #1: IntroductionIntroduce the PowerPoint® presentation. Example: Let's reviewsome key points presented in the video and how they relate toour site. This is also a good time for discussions and questionsas we go through the presentation.

Slide #2: Why is This ImportantDiscuss why this topic important to them. Discuss how electingnot to isolate energy sources before placing themselves in harmsway is like spinning a wheel-of-chance.

Slide #3: The Consequences for Not Locking OutDiscuss the potential consequences for not locking outequipment. This is also a good place to review or discussincidents that have occurred at your site. You may wish tochange the slide with statistics or pictures specific to your site.


Slide #4: 100% PreventableAccidents caused by the accidental release of stored energy are100% preventable.

Slide #5: Safety is a Personal ResponsibilityDiscuss how safety is a personal responsibility. Let your audienceknow what is expected from them and discuss any specificsrelevant to your site.

Slide #6: What is Lockout – Tagout?Discuss what Lock - Tagout is and its purpose.

Slide #7: Lockout – Tagout StepsReview the different types of energy used in your facility. Askthe class to identify the hazards associated with each type ofenergy. Ask the class what recommendations they have forcontrolling the common hazards. You may wish to add photosfrom your site.


Slide #8-9: Hazard Assessment and PlanningDiscuss the importance of hazard assessment and planning. Askthe class what should be included when planning. Review anyspecific policy requirements at your site.

Slide #10: Communication is CrucialDiscuss why communication is an important part of Lockout -Tagout. Discuss some potential worse case scenarios that couldoccur because of the lack of proper communication.

Slide #11: Shut Down ProceduresDiscuss the specific shut down procedures at your site.

Slide #12: Isolation of Energy SourcesDiscuss why it is important to isolate all sources of energy. Youmay wish to add pictures of equipment in your site and have theclass identify the different sources of energy and points ofisolation for each one.


Slide #13: Attaching Your Own LockReinforce the importance of each worker attaching their ownlock. Discuss the specific of locks and tags at your site.

Slides #14: Zero Energy StateDiscuss the importance and proper procedure for verifying zeroenergy state. Ask the class to identify different techniques forensuring zero energy state.

Slide #15-16: Safe Work PracticesDiscuss the importance of safe work practices while actuallyperforming the maintenance, service or repair on the equipmentsuch as the proper use of required PPE, body mechanic,housekeeping, etc.

Slide #17: Start Up ProceduresReview the proper steps for start up procedures.


Slide #18: Extend Shift ChangeDiscuss the specific requirement at your site for procedures tofollow when a lockout extends over a shift change.

Slide #19: Special Situations – ContractorsDiscuss the specific requirements at your site for theinvolvement of outside contractors.

Slide #20: Special Situations – Group LockoutReview the proper steps for group lockout procedures.

Slide #21: Worker Not Available to Remove Their LockDiscuss the specific requirements at your site for removing thelock of a worker who has left the premises. Discuss theconsequences if such an action has to take place.


Slide #22-23: SummaryReview key summary points with the class.


Lockout – Tagout ProceduresQuizName__________________________________ Date_________________

1. A key to preventing injuries due to the accidental release of stored energy is recognizing and respecting thepotential hazards in your work environment.

A. TrueB. False

2. Safety is a personal responsibility at your site.

A. TrueB. False

3. Good housekeeping is an important element of safe work practices during Lock - Tagout procedures.

A. TrueB. False

4. Before removing guards and placing your hands in a potential point of contact you should…

A. put on protective glovesB. isolate potential energy sources and lock them outC. check with your supervisorD. None of the above

5. Verifying zero energy state means.

A. Making sure all controls are in the off positionB. Blocking or releasing all stored energyC. Testing the equipmentD. Making sure your actions will not produce a release of energy or movement.E. All of the above


6. When should you give you key to another worker during Lockout - Tagout procedures?

A. If they need to remove your lock to test the equipmentB. If you are assigned to another tasksC. Only if complications developD. Never

7. Which is the first step in proper Lockout - Tagout procedures?

A. Identifying all energy sourcesB. Turning off the equipmentC. Isolating the energy sourcesD. Notifying affected workerE. Planning and hazard assessment

8. When Lockout - Tagout of equipment extends over a shift change, the incoming shift must…

A. Wait until the outgoing shift removes their locksB. Have the outgoing shift verify zero energy stateC. Attach their locks and tags prior to the outgoing shift removing theirsD. Use the outgoing shift's locks and tags to maintain continuityE. All of the above

9. Affected workers should be communicated only when you are ready to start up the equipment.

A. TrueB. False

10. What is the purpose of Lockout - Tagout procedures?

A. To protect you from the hazards associated with the accidental start up or release of energyB. To allow only authorized individuals to operate the controlsC. To identify energy sources for affect workersD. To use in place of a work permit to ensure your safetyE. All of the above


Quiz Answers1. A. True, recognizing and respecting the potential hazards is the first step and a key principle for

preventing injuries caused by the accidental release of stored energy.

2. A. True, safety is a personal responsibility at your site.

3. A. True, good housekeeping practices can help prevent slips, trips and falls and other incidents whilerepairing, servicing, or adjusting equipment.

4. B. Before removing guards and placing your hands in potential points of contact all energy should beisolated and locked out.

5. E. All of the above. Zero energy state exists when all energy in all elements of a machine have beenisolated, blocked and or dissipated such that operation of any control will not produce a release ofenergy or movement that could cause injury. The equipment has been tested and all controls havebeen returned to the off position.

6. D. Never give the key to your lock to another person.

7. E. Hazard assessment and planning is the first step in proper Lockout - Tagout procedures.

8. C. The incoming shifts attaches their locks and tags prior to the outgoing shift removes their locks andtags..

9. B. False, affected workers should be communicated with prior to locking out the equipment and againbefore the locks and tags are removed prior to start up.

10. A. The purpose of Lockout - Tagout procedures is to protect you from the hazards associated with theaccidental start up or release of energy.

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