Protect your team from the top hazard in food manufacturing: Tips to prevent lockout/tag out incidents
Workplace Safety & Prevention Services (WSPS) is a not-for-profit occupational health and safety association committed to ensuring every worker goes home healthy and safe at the end of the day. As your dedicated health and safety association for the food manufacturing industry, we are here to help with resources and support.
The food manufacturing industry and partners are working with WSPS to develop solutions that address the top risks for these businesses. In a recent study, this group identified the top risk in the sector as inadequate lockout/tag out. For more information and to access resources on the other top hazards in food manufacturing, visit this page.
In this article:
- What is lockout/tag out?
- Top 10 causes of inadequate lockout/tag out in the food manufacturing industry
- Prevent lockout/tag out incidents in your business with these 5 recommendations
- Lockout/tag out resources and training
What is lockout/tag out?
Lockout/tag out is the process of isolating the equipment from its energy source, draining the equipment of any energy that may be stored, and applying locks to secure it in a de-energized state. This allows you to safely interact with the equipment to clean, maintain and service it or remove jams or blockages. Improper lockout/tag out can lead to contact with dangerous energy. To be effective, a lockout program needs clear procedures, proper training, and supervision.
Top 10 causes of inadequate lockout/tag out in the food manufacturing industry
- Leadership Commitment
- Lack of Procedures (program)
- Inadequate Training
- Low Risk Perception/Acceptance of Risk
- Rushing
- Procedures Not Followed
- Inadequate Monitoring and Enforcement/Inadequate Lockout/Tag Out Devices
- Lockout Point Not Accessible
- Inadequate Procedure
- Inadequate Metrics (production rate, downtime, financial growth)
Prevent lockout/tag out incidents in your business with these 5 recommendations
The working group put forward five recommendations to address inadequate lockout/tag out in the
food manufacturing industry. Use the resources and training below to protect your business and your team from lockout/tag out incidents.
1. Provide information on the importance of effective lockout/tag out. Explain the risks of hazardous energy and provide examples of injuries/prosecutions resulting from inadequate lockout/tag out. Target the message to both workers and senior leadership.
2. Establish a guide for lockout/tag out program. Include the following details in your guidelines:
- Clearly outline the duties and responsibilities of all staff, including senior leadership.
- Conduct a needs assessment and identify what is needed to work safely (e.g. new or modified equipment, application of lockout/tag out, required devices, etc.).
- Provide clear, simple instructions for each piece of equipment, using visual aids where possible.
- Ensure all information is accessible and easy to understand.
- Include relevant legal requirements.
3. Establish a guide for lockout/tag out training. To ensure the training is effective, include the following in your guide:
- Ensure the training is both generic and equipment-specific.
- Include instruction on trainer competency, verification of knowledge transfer, supportive learning environment, and follow-up (two-way communication).
- Consider including references to legislation.
4. Establish standards for lockout points and devices. Ensure lockout points are identifiable, durable, and easily accessible. Consider incorporating lockout points into legislated Pre-Start Health and Safety Reviews.
5. Enhanced monitoring and enforcement. Internally, define:
- requirements,
- who is responsible
- coaching/mentoring opportunities
Learn more about lockout/tag out
Consulting
Machine Safety & Robotics Consulting - WSPS machine safety and robotics experts can improve your understanding of the machine safety hazards and develop or enhance a lockout tag/out program. Our experts will work with you to identify effective safeguarding options to protect worker safety.
Resources
- Lockout/tag out Training Guide (guide)
- Effective lockout training: 9 proven ways to get workers listening and learning (article)
- The hidden hazards of rushing at work: 5 tips to overcoming them (article)
- Is low risk perception a problem in your workplace? (article)
- Lockout/tag out worker resources – Staying Safe with Hazardous Energy, multi-language resources. Includes mobile-friendly video and ‘tips’ sheets. Available in French, Mandarin, Punjabi, Spanish, Tagalog, and English.
- Quick Safetry Tips: What details should be included in lockout/tag out training? (video)
- Quick Safety Tips: What are some key elements of a lockout program? (video)
- Duties & Responsibilities - The Occupational Health and Safety Act (article)
- How to Identify and Assess Your Hazards: Using the WSPS Hazard Assessment Tool (video)
- NEW! Pre-Start Health and Safety Review (PSR) Checklist for New Equipment
- NEW! Pre-Start Health and Safety Review (PSR) Checklist for Modified Equipment
- NEW! Pre-Start Health and Safety Review (PSR) Frequently Asked Questions
Training
Connect with an expert
If you’re ready to get started, or simply have questions about our services or approach, contact a WSPS specialist to find out more.
