Many companies face major challenges in implementing effective and compliant lockout/tagout programs—especially those related to lockouts.
       OSHA has special regulations to protect employees from accidental power-on or start-up of machinery and equipment.
       OSHA’s 1910.147 Standard 1 outlines guidelines for hazardous energy control commonly referred to as the “lockout/tagout standard,” which requires employers to “make plans and use procedures to secure appropriate lockout/tagout equipment to prevent employee injury.” Such plans Not only is it mandatory for OSHA compliance, but it is also mandatory for the overall protection and well-being of employees.
       It is important to understand the OSHA lockout/tagout standard, especially because the standard has been consistently ranked on the OSHA’s annual list of top ten violations. According to a report issued by OSHA2 last year, the lockout/listing standard was listed as the fourth most frequently cited violation in 2019, with a total of 2,975 violations reported.
       Violations not only result in fines that may affect the profitability of the company, but OSHA estimates3 that correct compliance with lockout/tagout standards can prevent more than 120 deaths and more than 50,000 injuries each year.
       Although it is essential to develop an effective and compliant lockout/tagout plan, many companies face major challenges in achieving this goal, especially those related to lockouts.
       According to research based on field experience and first-hand conversations with thousands of customers in the United States, less than 10% of employers have an effective shutdown plan that meets all or most of the compliance requirements. Approximately 60% of US companies have resolved the main elements of the lock-in standard, but in limited ways. Worryingly, about 30% of companies currently do not implement major shutdown plans.