Importance of Lockout Tags in Lockout Tagout Systems

Key Takeaways

• Lockout tags are safety warnings used during maintenance to prevent accidental startup. They are durable, brightly colored, and clearly labeled for visibility.
• Lockout tags are crucial for preventing accidental equipment activation, safeguarding workers, and ensuring smooth maintenance operations.
• Using tagout devices is essential for meeting OSHA safety standards, helping companies avoid fines, and ensuring a safe workplace environment.

What are Lockout Tags?

Lockout tags are an essential component of the lockout tagout system, designed to help prevent the unintended operation or startup of machinery during maintenance or repair work. These tagout devices serve as visual warnings to workers, indicating that the equipment is isolated from its energy source and should not be operated.

Tagout devices, such as the "Danger Do Not Operate" tag, should be used solely to alert all personnel that the equipment is under lockout tagout. These rectangular tags with rounded corners are typically made from durable materials like heavy-duty plastic, vinyl, or laminated paper to withstand harsh industrial environments. Lockout tagout tags are often bright, using bold colors like red, white, and black to grab attention. The contrasting colors make the warning message stand out and ensure that the tag is noticeable even from a distance.

Types of Lockout Tagout Tags

These different types of lockout tagout tags serve various purposes, ensuring that lockout procedures are communicated clearly and effectively, thereby enhancing workplace safety:

1. Equipment Lockout Tags: Equipment lockout tags serve as a visual warning that the equipment should not be operated because it is undergoing maintenance or repair. These tags typically include details about the energy control procedure, such as the person responsible, the date, and the reason for the lockout.
2. Danger Do Not Operate Tags: Danger Do Not Operate tags are among the most common and widely recognized types of lockout tags. These tags are used to warn personnel that a piece of equipment is not to be operated due to ongoing maintenance, repair, or a hazardous condition. The bold "Danger Do Not Operate" message is usually printed in large, clear letters on a bright red and white background.
3. Multilingual Tags: Multilingual lockout tags feature warnings in multiple languages, making them suitable for workplaces with a diverse workforce. These tags help ensure that safety messages are understood by all employees, regardless of their native language. This type of tag is particularly useful in global companies or locations where language barriers might otherwise pose a safety risk.
4. Custom Tags: Custom lockout tags allow companies to tailor the message and design to their specific needs. These tags can include company logos, specific instructions, or additional fields for detailed information. Custom tags are a great option for organizations that have unique lockout requirements or want to enhance their branding while maintaining safety.

Best Lockout Tagout Devices in the Market

This table provides an overview of top lockout tags on the market, highlighting their unique features and how they cater to various workplace safety requirements:

Why are Lockout Tags Important?

Lockout tagout tags are a crucial component of an energy control program. Here’s why they matter:

Prevents Accidental Startup

One of the primary functions of lockout tags is to prevent the unintended activation of machinery or equipment. When a machine is under maintenance or repair, there’s a risk that someone might unknowingly power it on, especially in a busy industrial environment.

A lockout tag serves as an unmistakable visual indicator that the dangerous equipment should remain off. By clearly signaling that work is in progress and the equipment is off-limits, tagout devices play a crucial role in preventing accidents that could result in serious injuries or even fatalities.

Improves Compliance with Safety Regulations

Compliance with safety regulations, such as those set by the Occupational Safety and Health Administration (OSHA), is not just a legal obligation but also a moral responsibility for employers. Lockout tags are often a mandatory component of a lockout tagout (LOTO) program under these regulations.
Using them correctly ensures that companies are meeting the specific requirements designed to protect workers from hazardous stored energy and avoiding significant penalties, including fines and legal action.

Communicates Important Information

Tagout devices are more than just warning signs; they are a communication tool that conveys essential information about the status of the equipment. A well-labeled tag typically includes the name of the individual who applied the lockout, the date and time the lockout began, and the reason for the lockout. This information is crucial in a workplace where multiple teams or shifts may be involved.

Facilitates Coordination Among Workers

In environments with multiple workers or shifts, lockout tags provide a clear indication of which equipment is being worked on. The presence of a lockout tag immediately signals to all workers that the equipment is not to be used, helping to prevent accidental interactions with the machinery. This level of clarity is essential for smooth operations and ensures that all workers are on the same page regarding ongoing maintenance or servicing activities.

If you’re not using lockout tags, are you meeting the OSHA requirements?

Not using lockout tags in your lockout tagout procedures puts your workplace at serious risk of non-compliance with OSHA regulations. The OSHA Standard Control of Hazardous Energy (29 CFR 1910.147) is designed to protect workers from hazardous energy that could cause injury or even death if machinery or equipment is accidentally energized during maintenance activities.

This standard requires that when machines or equipment are being serviced, energy sources must be isolated and locked out, and a clear warning must be provided to all workers involved. Without these tags, the lockout process is incomplete, which means that the equipment is not properly secured, and the safety of workers is compromised.

How do lockout tags, locks, and procedures work?

A lock is an energy isolating device that physically blocks the activation of equipment, while a lockout tag serves as a clear visual warning. Together, they form a strong safety barrier against accidental startup or energization. However, an effective lockout tagout goes beyond simply placing these devices on equipment; it involves a thorough set of procedures to isolate all hazardous energy sources, ensuring that the equipment remains locked out until maintenance is fully completed.

For example, if you had to change the blades on a press or guillotine. The lockout procedure would involve turning off the machine, locking the main power switch to prevent accidental reactivation, and attaching a lockout tag to clearly indicate that maintenance is in progress. The worker would also need to ensure that any stored mechanical energy, such as tension in the springs or pressure in hydraulic lines, is fully released before beginning the blade change, guaranteeing the machine remains inoperable during the maintenance process.

Best Practices for Lockout Tagout Device Use

Proper tagout device application is essential to the effectiveness of a lockout tagout procedure. For tags to serve their purpose, they must convey clear and detailed information that leaves no room for confusion.

1. Clear Labeling: Each lockout tag should include specific details that help communicate critical information to all personnel involved. This includes:

• Authorized Employee's Name: The name of the person who applied the lockout tag is crucial for accountability. It lets others know who is responsible for the lockout and who can remove the tag once the work is complete.
• Date and Time: Including the date and time of the lockout provides a clear record of when the equipment was de-energized. This helps track the duration of the lockout and ensures that the maintenance is performed within a reasonable timeframe.
• Reason for Lockout: Stating the reason for the lockout on the tag helps everyone understand the nature of the hazard and the importance of not operating the equipment. Whether it's for maintenance, repair, or inspection, the reason should be clearly stated.
• Department or Unit: Including the department or unit responsible for the lockout helps identify the area affected by the lockout and ensures that communication is clear across different teams within the facility.

2. Secure Attachment: The lockout tag must be securely attached to the equipment in a way that it cannot be easily removed or damaged. This is typically done using a strong cable tie or similar method that ensures the tag remains in place throughout the lockout period.

3. Visibility: The tag should be placed in a location where it is easily visible to anyone who might approach the equipment. It should be positioned in such a way that it catches attention immediately, ensuring that no one accidentally tries to operate the machinery.

4. Consistency: Consistency in the use of lockout tagout tags across a facility is important for creating a standardized safety protocol. All tags should follow the same format, use the same color schemes, and contain similar information to avoid any confusion or misinterpretation.

5. Tag Retrieval: Only the authorized employee who placed the tag, or someone they designate, should remove the tag. This prevents unauthorized removal, which could lead to premature startup of the equipment before it is safe to do so.

6. Tag Storage: When not in use, tagout devices should be stored in a designated location where they are kept clean, dry, and organized. Proper storage ensures that the tags remain in good condition and are ready for use whenever needed.

7. Periodic Inspections: Regular inspections of lockout tags and the overall lockout tagout system are necessary to ensure everything is functioning correctly. This includes checking that tags are still legible, securely attached, and being used properly according to established procedures.

Common Mistakes in Lockout Tag Use

One common mistake in lockout tag use is failing to provide detailed information on the lockout tag. Simply writing "Do Not Operate" without including the authorized employee’s name, date, or reason for the lockout can lead to confusion and miscommunication. Another frequent error is improperly attaching the tag, such as loosely securing it or placing it in a location where it’s not clearly visible. This can result in the tag being overlooked or accidentally removed, which compromises safety.

Lockout Tags FAQs

Can lockout tags be reused?

Yes, some lockout tags are designed to be reusable, especially those made from durable materials like heavy-duty plastic.

Are lockout tags safer than locks?

No, locks provide physical security by preventing equipment from being activated, while tags are primarily visual warnings; both should be used together for maximum safety.

What color are lockout tags?

Lockout tags are commonly red and white to ensure high visibility and to clearly signal danger.

Who can remove a lockout tag?

Only the authorized person who placed the tag, or someone they designate, can remove a lockout tag.

Is it illegal to cut a lockout tagout?

Yes, cutting a lockout tagout without proper authorization is illegal and violates safety regulations, potentially leading to serious consequences.