Lockout/Tagout for Thermoforming

Lockout/Tagout for
Control of Hazardous Energy
OSHA 10-Hour Outreach Training Program for the
Plastics Processing Industry
A Presentation of the SPI-OSHA Alliance
The Control of Hazardous Energy a.k.a.
Lockout/Tagout (LOTO)
The specific practices and procedures
necessary to disable machinery and
equipment so that employees performing
service and maintenance activities are
The Purpose of LOTO
• Prevent injuries from the unexpected startup
or release of stored energy
• Reduce the number of fatalities and injuries
• Establish a program and procedures for
controlling hazardous energy
Where to Begin?
• Job Safety Analysis (JSA)
• Develop Procedures
• Verify
• Train
• Audit
Preventing Unexpected Startup or
Release of Energy
Energy isolation:
• Minimize potential for inadvertent activation
and/or release of stored energy
• Ensure power to the machine is isolated and
locked at control points
• Use a method that cannot readily be
removed, bypassed, overridden or otherwise
Common Types of Energy Used in
• Electrical
• Mechanical
• Hydraulic
• Pneumatic
• Thermal
• Gravity
• Servicing and/or maintenance - activities
where employees may be exposed to
unexpected start-up or release of hazardous
energy including:
Installing and setting up
Adjusting, inspecting, modifying
Maintaining and/or servicing equipment
Lubricating, cleaning or unjamming
Tool changes or adjustments
• Set-up - Work to prepare a machine to
perform its normal production operation
• Lockout – Placement of lockout device on an
energy isolating device
• Lockout device – Device that uses a physical
means to prevent energizing of a machine or
• Energized - Connected to an energy source,
or containing residual or stored energy
• Energy isolating device - A mechanical device
that physically prevents the transmission or
release of energy
 Push buttons, selector switches and other
control circuit devices are not energy
isolating devices
Common Causes of Accidents
• Failure to identify risk
• Employees working outside of job description
• Inadequate training and/or comprehension
• Pressure to meet production goals
• Feeling they can do the task after watching
someone else do it
LOTO applies when:
• Employees are performing servicing and
maintenance, and there is a potential for
injury from unexpected start-up or release of
stored energy
• Service and maintenance that takes place
during normal production, if employee:
– Must remove or bypass a guard or safety
device; or
– Must place any part of their body into the
danger zone
Some Examples of when Lockout
is Required
Performing a set-up
Tool changing
Platen and toggle repair
Oven repair
While working on any electrical component
Repairs or maintenance on sheet transport
• Major plastic jams
Exception to LOTO
Minor servicing activities that take place
during normal production when
alternative effective protection is used
Minor Servicing During Normal
Production Operations
• Routine
• Repetitive
• Integral to the use of the equipment for
Alternative effective protection
such as:
• Interlocked gates and barriers
• Mechanical blocks, pins, bars, or locking
• Remote lubricators or other remote devices
Exceptions to LOTO While in
Production Mode May Include:
• Unjamming parts in form or trim station
• Wear plate changes
• Polishing the mold
• Cutting die adjustments
 Notching
• Foam placement in cutting die
Mechanical Safety Device
• Prevents platens from
closing when the mold is
being set
• Must have at least one
mechanical device on all
Form Stations and all Trim
Metal Pin inserted
into telescoping
post to prevent
travel of platens
Mechanical Safety Device
Metal pin inserted
to prevent any
travel of platens
Mechanical Safety Device
Metal bar inserted
to prevent any
travel of platens
Form or Trim Station Pinning Device
Metal pin inserted
to prevent any
movement of platen
Moveable platen
Form or Trim Station Pinning Device
Metal pin inserted
to prevent any
movement of platen
Sanding Minor Mold Blemish
Metal pins inserted
to prevent any
movement of platen
Method of Blocking Oven Travel
Accident #1
Amputation of 3 fingers
• Product stuck in forming/cutting area of
thermoforming machine
• Full-time press operator reached in to the
unguarded machine to dislodge part
• Forming molds closed on his hand
• Surgeons were unable to reattach fingers
Accident #2
Amputation of fingers
• Employee was attempting to clear material
which had become lodged in trim press
• Placed fingers into working envelope of the
cutting die
• The cutting die cycled, trapping the
employee’s fingers and thumb inside
• The employee’s fingers were severed and fell
into a grinder located below the die
Accident #3
Amputation of 3 fingers and thumb
• Machine Operator was removing jammed
parts from machine
• Inadvertently activated the remote switch
which activated the die ram
• The die ram lowered and amputated 3 fingers
and thumb
• Machine had been modified, side guards
removed and micro switches taped down
Accident #4
Arm Caught in Machine
• Machine operator on ladder reached over
plastic sheet on thermoformer and under the
sheet guide to readjust the guide
• Glove got caught in the unguarded chain and
sprocket drive
• Pulled arm into sprocket teeth and cycled
• After 1 cycle, arm was freed
Accident #5
• Employee operating thermoforming machine
on automatic mode
• Employee entered machine to make an
• Employee’s head caught in pinch point
causing fatal crushing injury
Core Components of an
Energy Control Program
• Energy control procedures
for each type of machine
• Training and retraining to
ensure employees
understand the program
• Periodic inspection to
ensure procedures are
being followed
Energy Control Program
Compliance with this
Sequence of Lockout
Energy Control Procedures
• Must be specific to each type of machine
and equipment you are working on
• Must include
– Statement of intended use of the procedure
– Steps for shutting down and securing machines
and equipment
– Steps for placing, removing, and transferring of
lockout devices
– Requirements for testing and verifying
effectiveness of lockout devices
Required Training
• Authorized employees
– Recognition of hazardous energy sources
– Type and magnitude of energy in the workplace
– Methods for energy isolation / control
• Affected employees
– Purpose and use of energy control procedures
• Other employees in work area
– Procedures related to restarting machines
Retraining Requirements
Retraining is required if:
• Change in job assignments
• Change in machines
• Change in energy control procedures
• Equipment or processes present new
• Inspections reveal deficiencies in employee's
knowledge of energy control procedures
• Retraining must reestablish employee
Periodic Inspections
• Performed at least annually
• Conducted by authorized
• Intended to correct
inadequacies identified in
• Certified
Certification Requirements
• Identification of equipment or machinery
• Date of inspection
• Names of employees involved in the
• Name of person(s) performing inspection
Application of the Energy Control
Procedure (Lockout)
Prepare for shutdown
Shut down equipment
Isolate all energy sources
Apply locks & tags
Release stored energy
Verify equipment isolation
Perform the task
Release from Lockout
Step 1: Prepare for Shutdown
• Understand equipment hazards
• Notify other workers of shutdown
Step 2: Shut down equipment
• Use the normal shutdown procedures
• Turn all switches to OFF/Neutral
Step 3: Isolate all Energy Sources
• Use energy isolation
devices in accordance
with established
procedures to prevent
transmission or release of
Step 4: Apply Locks & Tags
Apply locks and tags to:
• Valves
• Breakers/electrical
• Mechanical blocks
Valve lockout device
Step 5: Release or Block all
Stored Energy
• Discharge capacitors
• Block/disconnect
• Block or release
• Block elevated parts
• Relieve system
• Drain fluids
• Vent gases
• Allow system to cool
(or use PPE)
• Apply any additional
locks and tags
Step 6: Verify Equipment Isolation
• Check that other workers
are clear of potential
• Check that locking
devices are secure
• Attempt normal startup
• Return control to
Controls to verify
energy isolation
Step 7: Perform the Task
Step 8: Release from Lockout
• Ensure machinery is properly assembled and
all tools removed
• Ensure that employees are outside of danger
zones and are notified that devices are being
• Remove LOTO devices
– Must be removed by authorized employee
who applied it
The Job Safety Analysis Process
The Job Safety Analysis (JSA) process is a very
effective means of helping reduce incidents,
accidents, and injuries in the workplace. It is a
multi-step process.
•Basic Job Steps
•Potential Hazards
•Recommended Safe Job Procedures
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