KEEPING TABS ON LOTO

A robust Lock Out Tag Out (LOTO) protocol is vital to the smooth and safe running of any process where machinery is used – usually manufacturing facilities. Using the right kit to achieve that is an essential part of that process. ABUS a globally recognised provider of LOTO products and the experts in how they can best be used to provide a safe working environment for everyone.

The main aim of any LOTO programme is to avoid injuries and/or fatalities caused by the unintentional start-up of machinery that is undergoing maintenance, servicing or other outage: They are attached to switches, power outlets, valves, compressed air connections, and many more to prevent them being turned on or an unexpected release of power:

Lockout is a physical method of isolating or switching off machinery or equipment and preventing it from being turned back on - often a padlock, or a padlock and a device.

• Tagout is a highly visible warning that is attached to a lockout device to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or repair work

The statistics for injuries and fatalities in the workplace in the UK make sobering reading. In 2021/22 123 workers were killed at work (2021/22) and, according to the Labour Force Survey, 441,000 working people sustained an injury at work, costing the UK more than £16billion. Many of these could have been avoided with better health and safety policies and procedures in place.

We work with some of the UK’s major manufacturers and LOTO consultants to provide extensive solutions based on our market-leading range of padlocks which offer a solution no matter what the setting. We work with the safety team that is tasked with identifying risk areas and developing the LOTO policy. ABUS then liaises with the team on the type of equipment and devices to use, then providing a complete LOTO solution to site.

Safety Padlocks: a range of padlocks especially designed for LOTO. Key products in the ABUS safety padlock range are the ABUS 72 and 74 Series. The ABUS 72 Anodized Aluminium Series is very lightweight and can be engraved for personalisation and numbering and comes with the option of a cable shackle to it can be adapted for any application or environment. The plastic covered ABUS 74 Series safety padlocks are completely insulated against electric shocks and fulfils the golden rule of LOTO: one lock, one key, one operator. The 74 Series also feature another vital safety function, a key retention function. This means that the key can only be pulled out when the padlock is fully locked for fail safe operation. The ABUS 74 is available in ten different colours and can be personalised with engraving, ruling out any confusion on who takes on which tasks in the team to make it easy to organise and plan locking systems. For environments where the danger of sparks needs to be minimised the T84MB Brass Series is a safe bet.

ABUS safety padlocks are available with different shackle options in a variety of sizes to make them suitable for any LOTO application. Keyed Alike options are also available.

Lockout devices: the basic, mechanical hardware components, devices and hasps, used in conjunction with padlocks, to shut off machinery. They allow padlocks to be used easily and effectively on a number of critical points including control panels, compressed air outlets, power plugs, ball valves, circuit breakers, and switches so there is a solution for every eventuality.

Tag out: a full range of ABUS labels and stickers, accompanied with easily identifiable ABUS coloured padlocks and hasps, notify every one of the work in progress with many featuring a special area where the employee's name, department and other information can be written in with a permanent marker. This personalisation has proved to reduce the risk of accidental switch on. The safety labels are made of strong pressure-sensitive vinyl to withstand the rigours of industrial environments.

Shadow Boards: customers wishing to build a professional LOTO station can order a shadow board with capacity for 4, 10, 30 or 100 padlocks.

Safety kits: for companies wishing to establish a robust LOTO protocol could do worse than ordering ABUS lockout kits, a LOTO starter kit containing everything needed to lock out and tag different energy sources like valves, power plugs, or circuit breakers. The content of the kits can either be used specifically for single machines or working places or can become the basis of a much larger and comprehensive lockout program later on. For more complex and specific requirement, ABUS offers a ‘build your own’ custom safety kit facility.

One of our recent successes was working with Jaguar Land Rover at their Solihull facility, where the production line makes Range Rovers and the Land Rover Discovery SUVs. We provided a secure key and measured LOTO solution with the master key held within a safe on site with only key staff given access. On the shop floor each member of the maintenance team is issued with one lock and one key, maintaining personal responsibility for everyone. This solution, each with 300-400 padlocks will be rolled out across all of JLR’s sites in the UK.

To achieve a LOTO scheme that is of Jaguar Land Rover quality, speak to our LOTO expert Richard Whittaker. You can reach him on 0117 204 7000 or by emailing Richard.Whittaker@abus-uk.com