The first step to a well implemented Lockout/Tagout programme is to success is to develop and document a machine energy control policy. This Lockout/Tagout document establishes and explains the elements of your Lockout/Tagout programme, in such a way that it can be understood and applied in the workplace.

A Lockout/Tagout policy is not a one-time fix. It should be reviewed on an annual basis to ensure it's still relevant and effectively protects employees.

Lockout/Tagout procedures should take into account the specifics of any machine in your workplace. The procedures should document and detail the specific steps necessary for shutting down, isolating, blocking and securing equipment to control hazardous energy, as well as steps for the placement, removal and transfer of Lockout/Tagout devices.

Going beyond compliance, we recommend creating best practice procedures that include machine-specific photos identifying energy isolation points. These should be posted at the point of use to provide employees with clear, visually intuitive instructions.

Locate and identify all energy control points — valves, switches, breakers and plugs — with permanently placed and standardised labels or tags. Keep in mind that these labels and tags should be consistent with the machine-specific procedures from step 2.

Be sure to adequately train your employees, communicate Lockout/Tagout procedures and conduct periodic inspections to ensure your program is running effectively. Training should include regulatory requirements as well as specific Lockout/Tagout programme elements, such as your machine-specific procedures.

The following categories of employees should be trained:

• Authorised employees who perform the lockout procedures on machinery and equipment for maintenance.
• Affected employees who do not perform lockout procedures, but use the machinery that is receiving maintenance.
• Other employees who do not use the machinery, but are in the area where a piece of equipment is receiving maintenance.

With so many products on the market designed to help keep your employees safe, selecting the most appropriate solution for your application is the key to Lockout/Tagout effectiveness. Once selected, it's important to document and use devices that best fit the energy control points that regulate the flow of energy to specific machines.

Regularly review your Lockout/Tagout programme to improve it continuously. Proactively addressing Lockout/Tagout helps create a safety culture and maintain a world-class Lockout/Tagout programme, and avoids having to start over from scratch.

Maintain high levels of safety, and save time and money, by addressing every change in machinery and machinery setup in your Lockout/Tagout procedures and policy.