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Lockout-Tagout (LOTO) laws and regulations

Lockout-Tagout (LOTO) laws and regulations

minutes reading
Workplace safety is a legal requirement in many industries. When working on machinery and plant, the implementation of Lockout-Tagout (LOTO) is a crucial measure to protect employees from hazardous energy sources. To support companies in applying these procedures effectively, various international and national regulations and standards have been drawn up. These provide guidance on both machine design and the proper management of risks during maintenance and repair work. In this article, we take a closer look at the three most relevant guidelines in this area.
  1. The European Machinery Directive (2006/42/EC)

Within the European Union, the Machinery Directive provides the basis for safe machinery. This directive requires manufacturers to take measures that minimise the risk of unintentional start-up and hazardous energy.

The main requirements are:

  • Energy isolation: Machines must be equipped with lockable energy isolation points, such as main switches or shut-off valves, so that hazardous energy can be completely shut off.
  • Clear user instructions: Manuals should contain explicit guidance on how to safely isolate energy sources and apply LOTO methods.
  • Risk assessment: Manufacturers are required to carry out a systematic analysis of potential hazards and implement technical and organisational measures based on this.
  • Design safety: Manufacturers must ensure that machines do not restart automatically after a failure without a deliberate action, such as a manual reset.

The directive harmonises machine safety within the EU and lays a solid foundation for applying LOTO in practice.

 

  1. International standard: ISO 14118:2018

ISO 14118:2018 is a global standard that provides guidelines to prevent the unexpected activation of machinery. This standard emphasises both design and operational measures, effectively controlling risks during maintenance, inspection and cleaning.

Key aspects of ISO 14118:

  • Identification of energy sources: All possible hazardous energy sources, such as electrical, hydraulic, mechanical and thermal, must be identified and effectively isolated.
  • Technical solutions: The standard describes measures such as installing physical barriers, using blockades, and deploying warning systems to prevent inadvertent activation.
  • Training and communication: Workers and maintenance staff must be properly informed and trained on the risks of unexpected start-up and proper isolation procedures.

By implementing ISO 14118, companies worldwide can meet the highest safety standards and prevent workplace accidents.

 

  1. OSHA: US LOTO regulations

The US Occupational Safety and Health Administration (OSHA) has strict requirements for the management of hazardous energy sources. The guidelines, set out in standard 29 CFR 1910.147, focus specifically on maintenance and service operations.

Key obligations according to OSHA:

  • Energy management programmes: Employers must develop a detailed programme of procedures for isolating and securing hazardous energy.
  • Lockout and Tagout: Energy isolation points must be secured with physical locks (lockout) or warning labels (tagout) to prevent unauthorised activation.
  • Annual review: The energy control programme should be reviewed annually and, if necessary, adjusted to remain compliant with changing conditions.
  • Training and authorisations: Only trained and authorised personnel should perform and remove LOTO applications.

OSHA's regulations aim to protect workers from life-threatening situations, such as electrocution, entrapment and injuries from moving parts.

 

Harmonisation of safety standards

The Machinery Directive, ISO 14118 and OSHA guidelines complement each other and provide a strong basis for uniform safety practices. Together, they focus on:

  1. Designing safe machines with built-in energy isolation capabilities.
  2. Implementing clear procedures for energy management during maintenance and repairs.
  3. Training employees to recognise risks and take appropriate action.

Complying with these regulations not only ensures a safe working environment, but also helps companies comply with legal obligations. It significantly reduces the risk of workplace accidents, while protecting both employees and employers from the consequences of unsafe situations.

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