Factories and other industrial facilities are rife with safety hazards that can lead to all sorts of workplace injuries, from mild to fatal injuries. Many of these accidents are caused by non-compliance with lockout tagout procedures. Lockout tagout refers to a set of procedures or a system that can help ensure workplace safety and minimize the number of workplace injuries. It ensures that potentially dangerous machines and equipment are completely and properly shut off before maintenance work begins.
The Occupational Safety and Health Administration (OSHA) established the Lockout Tagout Standard (1910.147) for the control of hazardous energy. To follow this standard, an employee has to take the necessary steps to prevent a machine or piece of equipment from turning back on while under maintenance. This involves isolating the power source and, more importantly, implementing a proper lockout tagout procedure for an extra level of security.
The process prevents other employees from turning on and operating the machine when it’s unsafe to do so. A lockout tagout station can be instrumental in helping employees maintain a proper and compliant lockout tagout program, effectively keeping the workplace safe.
What is a Lockout Tagout Station?
Any facility that has to comply with the OSHA Lockout Tagout Standard (1910.147) will benefit from the use of a lockout tagout station. A lockout station provides a designated area to store and organize LOTO devices, making them easily accessible and ensuring that safety protocols are followed consistently. As such, it should be able to accommodate all manner of lockout tagout devices, such as padlocks, keys, inspection tags, and hasps.
It’s best if this station is easily visible and strategically placed in an easily accessible spot. However, it’s also important to make sure that this station can be locked and secured. This will prevent improper use by unauthorized personnel, as well as the accidental loss or damage of any of the devices.
Types of Lockout Tagout Stations
Lockout tagout stations come in various designs to meet the diverse needs of different industries and workplaces. Understanding the types available can help you choose the most suitable one for your specific requirements.
| Type of Station | Description | Advantages | Best For |
| Wall Mounted Lockout Tagout Station | Fixed installations on walls or vertical surfaces | Easy access, organized storage, high visibility | Fixed workstations, limited workspace |
| Portable Lockout Tagout Station | Compact and lightweight, designed for mobility | Flexibility, convenience, compact storage | Mobile tasks, large facilities |
| Lockout Tagout Station Cabinet | Larger units with multiple shelves and compartments | Ample storage, secure, durable | High-volume needs, secure environments |
Components of a Lockout Tagout Station
A typical lockout tagout (LOTO) station contains several essential components designed to isolate and secure hazardous energy sources during maintenance and servicing. Here are the primary components found in a LOTO station:
- Padlocks: They are used to secure the lockout devices in place, ensuring that energy sources cannot be re-energized until the lock is removed.
- Hasps: Lockout tagout hasps allow multiple workers to lock out a single energy source simultaneously. They are used in conjunction with padlocks and are essential for group lockout procedures.
- Tags: This lockout device provides critical information about the lockout, such as the person responsible for the lockout and the reason for the lockout. They are used in conjunction with padlocks and other lockout devices.
- Valve Locks: These are used to secure valves in a safe position, preventing the flow of liquids or gases. They come in various designs to accommodate different types of valves, such as ball valves, gate valves, and butterfly valves.
- Breaker Locks: Breaker locks are designed to lock circuit breakers in the off position, preventing the accidental re-energization of electrical circuits. They are essential for electrical lockout procedures.
Benefits of Having a Lockout Tagout Station
LOTO Stations Help Standardize LOTO Programs
A lockout tagout program will not only help with compliance but will also help prevent workplace injuries and fatalities. In fact, a formal lockout tagout program is an OSHA requirement.
Employees will also have to be properly trained to be able to execute the program. With the help of a lockout tagout station, employees will find it easier to stick to established routines which will make them less likely to deviate from the steps of the program. This will ultimately prevent employees from operating machines that are under maintenance, keeping maintenance employees safe from any accidental release of energy.
The goals of a good lockout tagout program are simple, but it will likely involve many steps and procedures to achieve these goals. A lockout tagout station will be able to help employees follow these steps to the letter with minimal confusion.
LOTO Stations Help Keep Track of All Devices
Think of a lockout tagout station as something akin to a key holder. A key holder is where members of a household hang all their keys at the end of the day to make sure that they can always be found in one place. Organizing keys can prevent loss and can help maintain efficient routines. A lockout tagout station works in much the same way.
Lockout tagout devices are the tools that physically prevent the accidental release of energy and the accidental operation of machines under maintenance. They are not easily replaceable; there are OSHA guidelines that specify the kind of devices that should be used in lockout tagout procedures.
Therefore, if a padlock gets lost or damaged, for example, it cannot be replaced by just any run-of-the-mill padlock from the hardware store. The same goes for other devices, such as lockout hasps and LOTO tags. Because these devices are vital to keeping the workplace safe, they should also be stored in a secure place. Any damage or loss can be disruptive to routines, can delay important maintenance work, and can also be dangerous for maintenance employees.
LOTO Stations Help Improve The Efficiency of Safety Procedures
Having an organized storage spot for lockout tagout devices can also help employees work with the same machines without confusion. This can minimize and even prevent mistakes that can be harmful to maintenance workers.
Additionally, lockout tagout programs need to be machine-specific. This means that if a facility has a variety of machines, it cannot have just one lockout tagout program that encompasses all those machines. Each machine must have its own lockout tagout program, and the employees who work with and on that machine have to be well-trained in executing that specific program.
Having a lockout tagout station in strategic spots or in close proximity to a machine will help maintain machine-specific programs. It eliminates confusion, helps enforce routines, and helps employees remember their training better.
Best Spots for Lockout Tagout Stations
Typically, a lockout tagout station is wall-mounted for easy and secure access. Because of the nature of a lockout tagout station and its functions, it’s best to install it in a strategic spot.
One option is to put the lockout tagout station somewhere central, in a spot that’s easily accessible to everyone who needs it. This placement is ideal if the station stores devices that can be used on multiple machines. Another option is to place the station right next to a machine, preferably in close proximity to the machine’s power source. This placement is best if the devices in that station are used for that specific machine only.
Maintenance and Best Practices for Using LOTO Stations
Below are key maintenance tasks and best practices for using LOTO stations effectively:
- Regular Inspection and Audits: Conduct regular inspections of LOTO stations to ensure that all components are in good working condition. Check for wear and tear, damage, or missing parts.
- Cleaning and Upkeep: Regularly clean the station and its components to prevent the accumulation of dust and debris, which can interfere with the functionality of the devices. Ensure that all locks, tags, and devices are stored properly to prevent damage and facilitate easy access.
- Replacement of Worn-Out Components: Replace any worn-out or damaged locks, tags, or devices immediately. Do not use faulty equipment, as it can compromise safety.
- Comprehensive Training: Provide comprehensive training for all employees on LOTO procedures, including the proper use of locks, tags, and devices.
- Standardized Procedures: Develop and implement standardized LOTO procedures that are easy to understand and follow. Ensure that procedures are specific to each piece of equipment and clearly outline the steps for isolating energy sources.
How Much Will A Lockout Tagout Station Cost You?
Lockout tagout stations don’t have to cost a lot of money to be effective and durable. A good lockout tagout station can set you back about $100 at least, but it won’t cost you more than $300, this varies greatly depending on the size and range of products the station comes with. At these prices, you’ll get a set of various lockout tagout devices as well as a durable and lockable case for security and storage.
Stations vs Kits: How They Can Work Together
Both a station and a kit can function and be used separately. A lockout tagout station provides a static and reliable place to store standard devices. A lockout tagout kit, meanwhile, is simply a collection of different lockout tagout devices that serve different functions.
However, the devices in a kit can also replace the devices that are usually found in lockout stations. In case any device is lost, damaged, or otherwise unusable, the devices in a lockout tagout kit can take its place.
Because OSHA guidelines also regulate the devices used in lockout tagout procedures, device replacements can’t just come from anywhere. Fortunately, having a kit on standby can help provide immediate solutions to any loss or damage.
Emerging Trends in Lockout Tagout Technology
Emerging trends in lockout tagout technology include the integration of digital and IoT systems, which provide automated tracking, real-time monitoring, and remote control of LOTO procedures. These advancements enhance compliance, efficiency, and safety by ensuring accurate documentation and immediate updates.
Additionally, innovations in LOTO stations, such as modular and customizable designs, improve storage and organization, making it easier to manage lockout devices. Advanced training tools, including virtual reality simulations, are also being developed to provide more effective and engaging LOTO training.
Lockout Tagout Station FAQs
Where should lockout tagout stations be placed?
Lockout tagout stations should be placed in easily accessible areas near high-risk equipment or where maintenance work frequently occurs to ensure quick access to LOTO devices.
What is the purpose of a lockout station?
The purpose of a lockout station is to provide a centralized and organized location for storing lockout tagout devices, ensuring they are readily available and properly managed to enhance workplace safety and compliance.
What are the requirements for lockout tagout stations?
Lockout tagout stations must comply with OSHA standards, be durable, provide adequate storage for all necessary devices, include clear labeling, and be placed in accessible locations to ensure effective lockout tagout procedures.
When should LOTO be used?
LOTO should be used whenever servicing or maintenance is being performed on machinery or equipment to prevent accidental energy release and protect workers from hazards.
What are the tools for LOTO?
The tools for LOTO include padlocks, lockout tags, lockout hasps, valve lockouts, circuit breaker lockouts, plug lockouts, and any other device necessary to isolate and secure energy sources.