Top 5 OSHA Lockout Tagout Violations

Top 5 OSHA Lockout Tagout Violations

December 11, 2019

For the fifth year running, Lockout Tagout is among OSHA’s top five most cited sources of workplace safety violations. According to statistics for the 2018 fiscal year, Lockout Tagout was ranked 5th in most cited OSHA violations, was also the fifth most common source of ‘serious’ violations, and ranked 2nd among ‘willful’ violations issued.

The top 5 most cited violations reported for 2018 were:
1) Fall Protection
2) Hazard Communication
3) Scaffolding
4) Respiratory Protection
5) Lockout / Tagout

Within and among the 2,923 total lockout violations cited in 2018, the top five sections cited were:

1. Failure to establish and implement a WRITTEN LOCKOUT TAGOUT PROGRAM
For successful implementation of Lockout Tagout in any company, LOTO System is a must! The employer shall establish a program consisting of energy control procedures, employee training and periodic inspections to ensure that before any employee performs any servicing or maintenance on a machine where the unexpected energizing, startup, or release of stored energy could occur and cause fatalities, the machines shall be isolated from the energy source and rendered inoperative.

2. Failure to develop, document and utilize MACHINE SPECIFIC PROCEDURE
Machine Specific Procedures (MSP) or Energy Control Procedures (ECP) are an integral part of any Energy control program. Inadequate awareness of isolation process can lead to big hazards & many lives could be affected by the resulted accidents. MSP helps to eliminate such possibilities of incidences by providing instruction in written format. Failing to develop a written MSP procedure or following the wrong procedures are one of the top 5 OSHA LOTO Violations.

3. Failure to conduct a PERIODIC INSPECTION of the energy control procedure
The employer shall conduct a periodic inspection of the energy control procedure at least annually to ensure that the procedure and the requirements are up to date.

4. Failure to provide TRAINING as described by OSHA
The employer shall provide training to ensure that the purpose and function of the energy control program are understood by employees and that the knowledge and skills required for the safe application, usage, and removal of the energy controls are acquired by the employees.

5. Failure to clearly OUTLINE the SCOPE and rules to be utilized, and means to enforce compliance
All employees are required to comply with the restrictions and limitations imposed upon them during the use of lockout. OSHA Standard establishes minimum performance requirements for the control of hazardous energy. Affected employees shall be notified by the employer or authorized employee of the application and removal of lockout devices or tagout devices. Notification shall be given before the controls are applied, and after they are removed from the machine or equipment.

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