During normal operation, machines are protected by safety devices. Manufacturers have installed functional safety technology that reduces the risk of injury to almost zero during normal operation. However, approximately one in five fatal accidents at work in Germany occur during maintenance, inspection, troubleshooting, repair, and cleaning work on machines and systems. The uncontrolled release of energy poses a major risk here, because employees can penetrate the interior of the machine by removing protective enclosures and come into contact with it there. However, this risk can be significantly reduced by safety measures. For this reason, more and more companies are relying on so-called lockout-tagout systems (LOTO for short).
How does lockout/tagout work?
The LOTO procedure consists of two main measures, broadly speaking:
- Lockout: A locking device such as padlocks, valve shut-offs, or blind plugs are attached to switches, valves, or other energy isolation points. This prevents the machine from being started unintentionally until the work is complete and blocks the supply of hazardous energy (e.g., electricity or compressed air).
- Tagout: A warning notice, known as a tagout tag, is attached to each lock. This informs uninvolved third parties of the reason for the work, the date on which the lock was attached, and the name and contact details of the key holder. Only the key holder is authorized to remove the lock with the tagout tag.
Why should every company use a LOTO system?
A correctly applied and implemented LOTO system offers numerous advantages:
- Reduction of accidents: The systematic locking and labeling of machines and systems during maintenance work significantly reduces the risk of accidents. This protects employees from hazardous energies such as electricity, compressed air, or technical gases.
- Cost savings: Fewer accidents also mean less downtime and lower repair costs. This can lead to significant savings in the long term.
- Increased efficiency: A well-implemented and actively used LOTO system ensures that maintenance work can be carried out safely and efficiently. This minimizes machine downtime and maximizes the company's productivity.
- Legal compliance: Although LOTO systems are not required by law in Germany, they can help to ensure compliance with occupational safety regulations and minimize legal risks. Disputes with the BG (German Social Accident Insurance Institution) and additional accident prevention measures can be avoided.
- Improving safety culture: The introduction of a LOTO system promotes a culture of safety and responsibility within the company. Employees are trained and made aware of safety issues, which leads to a safer working environment overall.
- Increased employee satisfaction: Employees feel valued because their employer cares about their safety and takes the necessary protective measures.
The successful implementation of a LOTO system requires a comprehensive program tailored to the company, which should include the following elements:
- LOTO process: Development of a process for the safe control of energy sources, taking into account legal requirements and operational conditions.
- LOTO one-pager: A specific lockout procedure (shutdown procedure) is developed for each machine, describing all relevant steps for securing it, pointing out any remaining residual hazards, and regulating its restart. Ideally, all information fits on one A4 page—hence the term LOTO one-pager.
- Labeling of energy interfaces: All necessary switches, valves, and plugs are clearly labeled to clearly identify the energy sources.
- Training: Employees, especially service technicians, must be comprehensively trained in the use of LOTO systems.
In addition, the LOTO process should be audited annually to ensure that all requirements are being met and that potential areas for improvement can be identified.
Legal framework in Germany
In Germany, the implementation of a LOTO system is not explicitly required, as is the case in the USA.
The LOTO principle contributes to the implementation of Section 10 of the German Industrial Safety Regulation (BetrSichV) and Section 6 of DGUV Regulation 3. These regulations require that maintenance work may only be carried out when the equipment is de-energized and that moving machine parts must be secured.
Are you interested in lockout/tagout or would you like to introduce a LOTO system in your company? Then please feel free to contact us.