Lockout/tagout Research Articles

Analisis Tingkat Pengetahuan Keselamatan dan Kesehatan Kerja (K3) Mengenai Lockout/Tagout (LOTO) terhadap Tindakan Tidak Aman (Unsafe Action) dalam Lockout/Tagout (LOTO) Pekerja Divisi Manufactur dan Divisi Enggenering pada PT. X Kabupaten Banyuwangi

PT.X is a business located in Banyuwangi district, East Java. PT.X is engaged in manufacturing which produces mineral water. PT.X Banyuwangi's work procedures have implemented K3 in its work processes. The Lockout/Tagout (LOTO) locking and marking system has been implemented, but unsafe behavior is still found by workers when carrying out work processes using the Lockout/Tagout (LOTO) system, such as not using PPE during machine repair/maintenance processes, and not installing tags. . . during repairs. This research aims to analyze the level of K3 knowledge about Lockout/Tagout regarding unsafe actions in implementing Lockout/Tagout among workers at PT. In general, this research is a type of quantitative research. The aim of using the crosstab method is to identify data patterns, such as the distribution of variable preferences based on the level of knowledge in carrying out actions. The results of the analysis were that 3 respondents in the good knowledge category carried out unsafe actions in the high category representing 37.5% of the total respondents, 5 respondents in the good knowledge category carried out unsafe actions in the low category representing 62.5% of the total respondents. total respondents. Then for the poor knowledge level category, there were 13 respondents who carried out unsafe actions in the high category, representing 56.5% of the total respondents, and 10 respondents who had poor knowledge levels carried out unsafe actions in the low category. representing 43.5% of the total respondents.

Implementation of Contractor Safety Management System (CSMS) PT. Waskita Karya on Rigid Pavement Subcontractor

Purpose: This study aims to evaluate the application of Contractor Safety Management System (CSMS) and its compatibility between the administrative stage and implementation in construction projects, particularly focusing on the Kutanegara region in Indonesia. Recognizing the prevalence of work accidents and delays attributed to discrepancies in CSMS, the research seeks to assess the alignment between CSMS policies and their execution in the field. Methods: The research adopts a descriptive qualitative approach to evaluate the application of CSMS. Data collection employs triangulation, combining observation, interviews, and documentation review. Key informants, including main and supporting stakeholders, are selected through purposive sampling techniques to provide insights into CSMS implementation and its effectiveness in ensuring workplace safety and compliance. Results and Discussion: The evaluation of CSMS application reveals inconsistencies between administrative policies and their implementation in the field. Specifically, discrepancies are identified in the installation of vision, mission, and policy statements (16%), K3 signs and smoking bans (42%), warning signs and evacuation directions (53%), and the management of electrical panels and Lock Out Tag Out (LOTO) procedures (37%). While these inconsistencies are categorized as minor, they highlight the need for continuous improvement and alignment between CSMS policies and practices to mitigate work accidents and delays effectively. Implications of the Research: The findings of this study have implications for construction project management and safety practices, emphasizing the importance of aligning CSMS policies with on-site implementation to enhance workplace safety and efficiency. By identifying discrepancies and areas for improvement in CSMS application, the research provides insights into strategies for enhancing safety protocols and reducing the risk of work accidents and delays in construction projects. Originality/Value: This study contributes to the existing literature by addressing the gap in research regarding the alignment between CSMS policies and their implementation in construction projects, particularly in the Indonesian context. By employing a qualitative approach and triangulating multiple data sources, the research offers valuable insights into the effectiveness of CSMS in ensuring workplace safety and compliance. The findings underscore the importance of continuous improvement and adherence to safety protocols in construction projects, ultimately enhancing the overall quality and efficiency of project delivery.

A novel approach for predicting Lockout/Tagout safety procedures for smart maintenance strategies

A novel approach for predicting Lockout/Tagout safety procedures for smart maintenance strategies

Integration of operational lockout/tagout in a joint production and maintenance policy of a smart production system

Accidents during maintenance operations are frequently occurring and sometimes even fatal. The lack of energy locking is one of the main factors of accidents during maintenance. The Lockout/Tagout (LOTO) process aims to ensure the safety of workers by providing a control of equipment energies before and after preventive or corrective maintenance activities. However, LOTO is often seen as an unnecessary delay that increases production costs. The objective of this work is to minimize production and inventory costs of finished products, while guaranteeing the safety of workers during maintenance activities by the implementation of operational LOTO actions, which allows for production continuity during the securing of energy sources. This work studies the problem of production and maintenance planning of a smart production system that deteriorates according to its age affecting its reliability and availability. The system under study consists of a production unit processing a single type of parts and exposed to random failures and repairs. The decision variables for this control problem are the machine age dependent production and preventive maintenance rates of the machine. The proposed model is based on the stochastic optimal control theory and the optimality conditions are obtained by the dynamic programming approach. Such conditions are of the Hamilton-Jacobi-Bellman (HJB) type and have been solved by numerical methods for concrete industrial case applications. The developed model is validated using a numerical example and a sensitivity analysis is conducted to study the behavior of the system related to the variations of some parameters. A comparative study shows that the proposed operational LOTO strategy performs better than a traditional LOTO strategy in optimizing maintenance operations and reducing incurred costs. This study proposes new managerial policies in terms of joint management of production, maintenance and safety.

Towards intelligent manufacturing system safety strategies: generating LockOut/TagOut sheets by Machine Learning – a case study

Lockout/Tagout (LOTO) is a procedure that considerably reduces the risk of work-related accidents by isolating and securing the energy sources of industrial equipment. In the Industry 4.0 era, safety procedures must also evolve towards more intelligent procedures supported by technologies such as machine learning or the Internet of Things. The LOTO procedures follow sheets that indicate how to perform the security. These sheets, manually generated, could be generated automatically to optimize the LOTO procedure. This paper proposes a methodology to achieve an automatically generation of such sheets. The first sub-objective is to extract information from the available LOTO sheets provided by the industrial partner and in a second step to develop different text mining methods and word similarity search algorithms. Several options are presented to address the second sub-objective, which aims to generate the sheets from the previously obtained dataset. Finally, the future steps of this research work will be presented. In practice, an automatic generation of such sheets would enable to quickly implement the LOTO procedure for the first time on an industrial equipment, which would reduce the risk of accidents.

Development of an Internet of Things (IoT) based Lockout/Tagout (LOTO) device for Accident Prevention in Manufacturing Industries

Despite all the technological advances, safety remains the biggest challenge in Industries. Each year, thousands of electrocutions and hundreds of machinery-related accidental deaths are happening. A number of these accidents involve inadequate, unauthorised or improper use of hazardous energy control procedures, also known as lockout/tagout (LOTO) procedures. Although the organizations like Occupational Safety and Health Administration (OSHA), USA, The National Institute for Occupational Safety and Health (NIOSH) and others have defined a very detailed LOTO procedure, however, these LOTO procedures have many manual activities. With the emergence of IoT (Internet of Things) these manual activities can be combined with automated activities thereby enhancing safety. IoT based devices can be implemented to ensure authorized access to hazardous areas around operating machinery, improve documentation and monitoring of service during repair and/or maintenance that requires shutdown of the machinery, and prevent unexpected, unauthorised start up, or movement during maintenance of machinery or related activities. Acknowledging the importance of IoT enabled safety devices NIOSH is also exploring the possibility of implementing IoT based technologies to provide intelligent machine monitoring as part of a comprehensive LOTO program. This paper presents the development of an IoT based LOTO device, its implementation and effectiveness in improving safety and accident prevention. It is found that the IoT based LOTO device is effective in accident prevention (from 47 to 0 incidents) and its performance (from 697 to 349 Seconds) is reliable.

Analysis of industrial accidents causing through jamming or crushing accidental deaths in the manufacturing industry in South Korea: Focus on non-routine work on machinery

Industrial accidents caused by equipment (machinery) occur in various forms, such as jamming, cutting, and crushing. Among them, various precise and dangerous machines and equipment in the manufacturing industry continue to be used despite the several regulations established and efforts made. This study analysed the accidental deaths caused through jamming or crushing during non-routine work, in the manufacturing industry from 2014 to 2018. The analysis was conducted on 203 cases of non-routine work among 359 fatalities. The maintenance, repair, inspection, replacement, adjustment, cleaning, and removal of foreign substances were classified into non-routine work. Owing to the use of various machineries and equipment in the manufacturing industry, specialised knowledge is required for their maintenance and management, as well as daily work. Since various types of equipment (machinery) are used in the manufacturing industry, expertise to safely use equipment is required to prevent industrial accidents that may occur during work using this equipment. In South Korea, where heavy industry and chemical industry have developed, many accidental deaths due to non-routine work have been reported under these conditions. Non-routine work accounted for 56.5% of jamming accidents, which were caused by seven major equipment such as conveyor, mixer, food manufacturing equipment, crushing machine, injection moulding machine, press machine, and industrial robot. In addition, the employees did not fully comply with the basic safety rules, such as not turning off the power or using lockout-tagout (LOTO), during the maintenance work. Finally, various measures were proposed to prevent accidental deaths resulting non-routine work.

Enhanced Productivity With Lockout/Tagout Alternatives: Exploring Alternative Protective Measures

Unquestionably, Lockout/Tagout (LOTO) saves lives in all manufacturing and processing segments, but it can also be a drain on productivity. Additionally, some types of diagnostic and setup work require active power sources, which can lead to workers bypassing LOTO procedures. LOTO alternative protective measures (APMs) that are compliant with the Occupational Safety and Health Administration's (OSHA's) minor servicing exception (MSE) present an opportunity to enhance productivity and help reduce the incentive for workers attempting to bypass critical safety procedures. This article explores the use of LOTO APMs, how they can improve productivity, their safety and financial benefits, and the appropriate locations for their use.

A Study on the Improvement of Methods for Human Error Prevention using a Smart MCC System

South Korea has seen remarkable growth in the world since its liberation. However, the incidence of industrial disasters has increased during its rapid industrial development, and South Korea is currently ranked as one of the Organisation for Economic Co-operation and Development (OECD) countries, with high rates of industrial accidents. In particular, the misuse of the Motor Control Center (MCC) panel switches leads to serious accidents caused by human error. Therefore, this study introduced and proposed the use of a smart MCC system for human error prevention to improve the inadequacies of the current Lock-Out, Tag-Out (LOTO) program. The present study compared and analyzed the existing and smart MCC systems. In addition, the durability and operation of the new system were verified by an authorized agency. Furthermore, a survey of users (operators and operating departments) reported good reliability, user convenience, and safety accident prevention of the new system. The on-site application of this system will contribute to the effective operation of electrical facilities and the prevention of the misuse (human error) of MCC switches and the development of accident prevention solutions combining ICT technology. Keywords: Human Error, System, Motor Control Center (MCC) Panel, Accident Prevention

Leveraging IIoT to Improve Machine Safety in the Mining Industry.

Each year, hundreds of mine workers are involved in machinery-related accidents. Many of these accidents involve inadequate or improper use of lockout/tagout (LOTO) procedures. To mitigate the occurrence of these accidents, new safety methods are needed to monitor access to hazardous areas around operating machinery, improve documentation/monitoring of maintenance that requires shutdown of the machinery, and prevent unexpected startup or movement during machine maintenance activities. The National Institute for Occupational Safety and Health (NIOSH) is currently researching the application of Internet of Things (IoT) technologies to provide intelligent machine monitoring as part of a comprehensive LOTO program. This paper introduces NIOSH's two phase implementation of an IoT-based intelligent machine monitoring system. Phase one is the installation of a proof-of-concept system at a concrete batch plant, while phase two involves scaling up the system to include additional sensors, more detailed safety/performance metrics, proximity detection, and predictive failure analysis.

Investigation of Lockout / Tagout Procedure Failure in Machine Maintenance Process

Lockout/tag out (LOTO) refers to specific practices and procedures to stop the release of hazardous energy and turnoff machinery and equipment during service or maintenance activities. An effective LOTO system will ensure the workers are protected from the unexpected conditions during maintenance activities. This paper focus on incidents of LOTO system failures in an electricity power industry. LOTO system had implemented for many years in the company, but many incidents of LOTO system failure was still happened. The purpose of the research was to investigate the cases of incident caused by LOTO procedure failures. The research was conducted using descriptive analytical approach to analyse the cases of incident to find the root causes and develop the solution. Main data used in the research was document of incidents and was analysed by Systematic Cause Analysis Technique (SCAT). The result of investigation showed the root causes of LOTO system failure were caused by individual, job and management factors. Based on SCAT chart synthesis, the control actions were identified. The identified control movement were improve operational procedure of LOTO and proposed job description of supervisor. Evaluation of control action concluded that basically the suggestions were feasible to implement and some adjustments were needed due to implementation.

A Mathematical Model: A Flexible Manufacturing System, Prone to Error, Making Two Products Each with Stochastic Demand Schedules

Lockout/tagout (LOTO) is practiced in manufacturing facilities to ensure safety during machinery maintenance procedures. In flexible manufacturing systems, human error (HE) is a major source of accidents and process deviations. Special measures are needed to minimize occupational risk and increase operational efficiency. In this article, we study a production planning problem involving a failure-prone production system meeting two types of demand and we discuss the associated decision-making process. The aim is to develop an optimal, robust and flexible control strategy that facilitates the integration of LOTO into corrective maintenance (CM) and ultimately into production. The influence of HE on flexible manufacturing systems (FMS) is viewed in terms of production and maintenance planning. The frequency of machine repair depends largely on HE. The intrinsic costs of shortage, inventory and CM are optimized over an unbounded planning horizon. Analytical formalism is combined with discrete event simulation, as well as design of experiments (DOE) and a genetic algorithm (GAs) to identify the optimal planning of production and CM with mandatory LOTO. An illustration and sensitivity analysis are proposed to express, in quantitative terms, the usefulness and efficiency of the proposed approach.

Correlation Between Company’s Lock Out Tag Out (LOTO) System with LOTO Implementation Behavior of Mechanic in Plant Department

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Self-audit of lockout/tagout in manufacturing workplaces: A pilot study.

Occupational health and safety (OHS) self-auditing is a common practice in industrial workplaces. However, few audit instruments have been tested for inter-rater reliability and accuracy. A lockout/tagout (LOTO) self-audit checklist was developed for use in manufacturing enterprises. It was tested for inter-rater reliability and accuracy using responses of business self-auditors and external auditors. Inter-rater reliability at ten businesses was excellent (κ = 0.84). Business self-auditors had high (100%) accuracy in identifying elements of LOTO practice that were present as well those that were absent (81% accuracy). Reliability and accuracy increased further when problematic checklist questions were removed from the analysis. Results indicate that the LOTO self-audit checklist would be useful in manufacturing firms' efforts to assess and improve their LOTO programs. In addition, a reliable self-audit instrument removes the need for external auditors to visit worksites, thereby expanding capacity for outreach and intervention while minimizing costs.

Findings From the National Machine Guarding Program–A Small Business Intervention

The purpose of this nationwide intervention was to improve machine safety in small metal fabrication businesses (3 to 150 employees). The failure to implement machine safety programs related to guarding and lockout/tagout (LOTO) are frequent causes of Occupational Safety and Health Administration (OSHA) citations and may result in serious traumatic injury. Insurance safety consultants conducted a standardized evaluation of machine guarding, safety programs, and LOTO. Businesses received a baseline evaluation, two intervention visits, and a 12-month follow-up evaluation. The intervention was completed by 160 businesses. Adding a safety committee was associated with a 10% point increase in business-level machine scores (P < 0.0001) and a 33% point increase in LOTO program scores (P < 0.0001). Insurance safety consultants proved effective at disseminating a machine safety and LOTO intervention via management-employee safety committees.

Findings From the National Machine Guarding Program: A Small Business Intervention: Lockout/Tagout.

Failure to implement lockout/tagout (LOTO) procedures adversely affects the rate of work-related fatalities and serious traumatic injury and is one of the most frequently cited Occupational Safety and Health Administration standards. This study assesses the impact of a nationwide intervention to improve LOTO in small metal fabrication businesses. Insurance safety consultants conducted a standardized and validated evaluation of LOTO programs and procedures. Businesses received a baseline evaluation, two intervention visits, and a 12-month follow-up evaluation. The intervention was completed by 160 businesses. The mean LOTO procedure score improved from 8% to 33% (P < 0.0001), the mean program score went from 55% to 76% (P < 0.0001), and the presence of lockable disconnects went from 88% to 92% (P < 0.0001). This nationwide intervention showed substantial improvements in LOTO. It provides a framework for assessing and improving LOTO.

Case for developing online lockout tagout training

Case for developing online lockout tagout training

Energy isolation lockout tagout for higher education

Energy isolation lockout tagout for higher education

Application of Lockout & Tagout System in the Coalmine Industry

In order to change the present of safety management, the safety issues are analysed in this article, which are caused by the unexpected release of energy when producing and maintaining in coal mine industry. The importance of Lockout & Tagout (LOTO) system for safety management of coal mine industry was also expatiated. And then the process of LOTO System is introduced, the requirements and methods of LOTO System operated in coal mine are raised. It has important significance in reinforcing the safety management, enhancing safety production persistent effect mechanism construction and realizing safety production in coal mine.