When to use Full Lockout/Tagout vs. Alternative De-Energization Procedures (ADP)

LOTO vs ADP graphic
LOTO
Lockout/Tagout is required for all Servicing and Maintenance Activities where the employee may be exposed to the unexpected energization or startup of the equipment or release of hazardous energy.
ADP
ADP is an exception to LOTO in certain situations that are minor, routine, repetitive, and integral to the production process. It must enable employees to safely perform the servicing task without being exposed to the unexpected energization or activation of the equipment or the release of stored energy.
– MACHINE SPECIFIC
LOTO allows any task to be completed anywhere on the machine.
– TASK SPECIFIC
Activities can be performed only for the approved tasks in an approved area of the machine.
– WHEN DOES THE ACTIVITY OCCUR?
  • Anytime an employee must place his/her body part into a point of operation in the equipment
  • Anytime an employee must place his/her body part in the path of a moving machine part
  • Anytime a team member must remove or bypass a safety guard or safety device.
– WHEN DOES THE ACTIVITY OCCUR?
  • Activity must be conducted during normal production operations
  • While machine or equipment is actually performing it’s intended production function
– TASKS MAY:
  • Be major work
  • Occur infrequently
  • Be long in duration (multiple hours, shifts, days)
  • Require extensive disassembly
  • Require multiple employees to service
  • Be completed by authorized employees only
– TASKS SHOULD:
  • Be short in duration
  • Be relatively minor in nature
  • Occur frequently during the shift, day or week
  • Be expected to occur regularly
  • Not involve extensive disassembly
  • Represent predetermined cyclical activities
  • Usually be performed by operators, set up, service or maintenance personnel
  • Minimally interrupt the production process
  • Exist even at optimal operating levels
– EXAMPLES OF WHEN TO USE LOTO:
  • Removing/replacing motors
  • Removing/replacing equipment transmission components (belts, chains, sprockets, etc.)
  • Removing/replacing actuating mechanisms (pneumatic cylinders, shafts, pistons, etc.)
  • Removing dies, molds, etc.
  • Removing jams from point of operation or points of power transmission
  • Activities that require a hoist or more than 1 person to complete

Learn more about the LOTO process

– EXAMPLES OF WHEN TO USE ADP:
  • Surface cleaning or equipment
  • Lubrication of equipment using lubrication ports
  • Manual alignment of guide rails
  • Manual adjustment for product size changes
  • Minor jams outside the point of operation or power transmission
  • Changing equipment components designed for quick change over that do not require multiple tools, multiple persons, or additional mechanical aids to replace
  • Cleaning

Learn more about the ADP process