Click the arrow to begin Course #: 37848 2010© General Motors LLC. All rights reserved. No part of this material may be reproduced in any form or by any

Lockout Energy Control

GMS Overview


GMS Overview

Click the arrow to beginCourse #: 378482010© General Motors LLC. All rights reserved. No part of this material may be reproduced in any form or by any method (photocopy, microfilm, digital, etc.) without the written permission of General Motors LLC, educational purposes included.


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Table of Contents

Resources

Requirements for Lockout Energy Control

Why Lockout Energy Control?

Leadership Action

Knowledge Check


Objectives

The purpose of this module is to provide leaders with the summary of the Lockout Energy Control Program as one of the GMs’ risk control programs.

The module includes– Awareness of historical issues– Description program requirements– Control measures– Leadership actions




What Is Lockout?

Lockout is a technique used to prevent the release of hazardous energy, or to prevent the hazardous energy from escaping.


What Is Hazardous Energy?

Hazardous energy may be any energy that could cause harm to a worker such as:

Electrical

Mechanical (such as pneumatic, hydraulic, springs, parts moved by gravity, spinning flywheels, pressurized systems, etc.)


Why Lockout?

Workers are seriously injured or lose their lives because they failed to control hazardous energy while working on, maintaining or repairing machinery and equipment.


The “Fatal Five” Main Causes of Lockout Injuries

Failure to stop equipment

Failure to disconnect from power source

Failure to dissipate (bleed, neutralize) residual energy

Accidental restarting of equipment

Failure to clear work areas before restarting


Lockout Case

Plant Location: Body Systems Paint

Description of Incident:

Two electricians were assigned to replace the shunt trip mechanism on a 1200 amp General Electric Breaker in the Paint Mix Motor Control Center.

The Buss Plug Feeding the breaker was locked out in accordance with the posted lockout placard and power at the breaker feed on top of the breaker was checked and verified to be zero.


Lockout Case


Description of Incident:

As one of the team members began work, he laid his screwdriver across two legs at the bottom of the breaker that he assumed were also de-energized.

The handle of the screwdriver rolled off the leg it was resting on causing the metal screwdriver shaft to contact the legs.

There was a flash and two substation breakers tripped.

The team member received a flash burn to his wrist and was temporarily blinded by the flash. Investigation revealed that the breaker had a redundant power feed from an adjacent breaker cabinet.


Lockout Case


Injury Status: First Degree burn to the right forearm

Contributing Factors and Comments

Lockout placard did not reflect that the breaker had a redundant power feed from an adjacent panel and that both panels needed to be locked out in order to achieve a zero energy state in either breaker.

The team member did not verify zero energy at the bottom of the breaker bar.


Lockout Fatalities1973 to 2004

35%

65%

Lockout-re-lated

Non-lockout Related

GM Occupational Fatalities Lockout Related Fatalities

57%

12%

19%

12%Electricians

Millrights

Machine Repair Persons

Other Trades




What Does a Hazardous Energy Control Program Include?

Design-In Safety requirements

Lockout procedures

Monitored Power Systems

Training

Warnings and placards


Program Requirements

The lockout program consists of other components which must be considered– GM Policy– Laws and regulations – Personnel roles and responsibilities– Procedures (SOPs)– Inspections

We will review each of these in the next few slides.


GM PolicyLockout is required where employees or contract persons may be exposed to hazardous energy that could cause injury. Exposure means that the employee or contract person is in a position to be injured by released energy.


GM PolicyWhere an employee or contract person is exposed to potential injury from expected machine energy or motion, the exposure must be eliminated. If the exposure cannot be eliminated, the machine will be locked out.

This policy is designed to meet regional regulatory requirements.


Local Regulations

Depending on your location, you may also be subject to additional governmental regulations regarding lockout.


Lockout Implementation Roles

Who do you need to be concerned about with regard to lockout?

There are three defined roles:

Affected person

Authorized person

Competent person



Affected person

A person who performs duties in an area where the lockout energy control procedure is implemented and service or maintenance tasks are performed.

An affected person does not service or maintain equipment or machines and is not responsible for implementing the lockout energy control procedure.



Affected person

Authorized person

A person who performs service or maintenance tasks on machines and equipment. Lockout is used by an authorized person for his/her own protection.



Affected person

Authorized person

Competent personA management-designated person who has the knowledge and skills to inspect for adherence to Lockout/Hazardous Energy Control Program requirements.

The management-designated person must have completed General Motors lockout / energy control training.


Training Requirements

Authorized and Competent Persons must be trained to– Recognize hazardous energy– Identify types of energy– Understand methods and means of isolation and

energy control– Identify elements of the Lockout Energy Control

Procedure – Have on-the-job familiarization with energy control

and isolating devices


Basic Concepts of Lockout Hazardous Energy Control

1. Evaluate jobsite for hazardous energy

2. Identify each hazardous energy source

3. Determine whether any hazardous energy found can be eliminated or controlled

• If yes, then eliminate or control the energy• If no, then implement lockout procedures

4. Perform action and verify


Lockout Energy Control Program

Each Lockout control program should include the following:

Facility Lockout Procedure

Purpose of Procedure

Training Requirements

Sequence of Lockout Procedure

Procedure for Restoring Equipment to Service

Lock Removal Procedure


Lockout Procedure

There are well-established procedures at all GM facilities for performing lockout. These procedures address:

De-energizing and locking out equipment

Restoring power to equipment

Removing another worker’s personal lock


Lockout Procedure

As a leader, the two most important points for you to remember are:

Only persons that are adequately trained and issued a GM personal lock are permitted to enter a hazardous work area

Never remove or tamper with another worker’s lock without following the proper procedure


Inspections

An inspection must be conducted annually

Primary responsibility: management-designated employee, such as a general supervisor, supervisor, or other competent employee

Inspections will be a certified by a member of management


Inspection Requirements

Inspections may use a representative random sample that considers all:

– Authorized persons– Machines– Processes

Inspections must include interviews to assess employee knowledge of policies and procedures

– Interviews must be documented


Inadequate Lockout and SOP

The supervisor should be notified if:– The machinery or equipment does not have

adequate energy control devices for lockout

– The machine or equipment must be energized during the maintenance or servicing task and workers may be exposed to a hazard


Safe Operating Procedures (SOPs)

An SOP must be created if:– Engineering and Maintenance determine

that a hazardous condition identified in an Inadequate Lockout Form cannot be immediately eliminated

– The machine or equipment must be energized during the maintenance or servicing task and the maintenance person will be exposed to a hazard.



An SOP provides specific directions for eliminating exposure and/or controlling an energy hazard




SOPs can eliminate exposure using:– Modified work methods– Repositioning– Safeguarding devices– PPE




SOPs can eliminate exposure using:– Modified work methods– Repositioning– Safeguarding devices– PPE

Each SOP is specific to the equipment or machine and to the task to be performed


SOP Requirements

Each SOP must contain the following information:– Machine/equipment identifier– Date– Written by– Task– Hazard(s)– Purpose– Precautionary safety measures

Types of Energy and Lockout Devices

Types of Energy and Lockout Devices


Energy Types and Devices

Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity

Stored Mechanical Energy, Including Momentum

Special Energy Systems

Multiple Energy Systems



Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity





Energy Types and DevicesCylinder

Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity






Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity



Multiple Energy Systems Pneumatic valve

Electrically powered pneumatic valve


Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity





Point of insertion

Pin



Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity




Robot counterbalance spring

Spindle on a drill press



Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity






Electrical Energy

Hydraulic Energy

Pneumatic Energy

Gravity





Lockout Device

A lockout device provides protection by preventing the equipment or machine from becoming energized

Lockout devices and identification labels must be:

– Durable– Standardized– Identifiable– Substantial


Common Lock Initiative

Each GM facility is directed to provide each employee authorized under the GM Lockout Energy Control Program with a common personal lock to be used to lock out energy sources in accordance with the program.

“One person – one lock – one key.”


Locks

Safety locks are to be:

Used only by the authorized person

Used for lockout purposes only

Carried during work hours


Lock Identification Tags

A tag:– Is not a substitute for a lock– Offers no protection– Can be easily removed,

overlooked, or defeated

An identification tag is to be used only in conjunction with an approved lock


Types of Lockout Devices

Scissors

Cable or chains

Safety blocks

Wedges

Adjustable safety block

Gravity pins


Placard PurposePlacards are designed to assist in identifying:

Types of energy that must be controlledLocations of the energy isolating devicesProcedural steps for shutting down, isolating, blocking, and securing machines or equipment Procedural steps for the placement, removal, and transfer of lockout devicesRequirements for verifying neutralization of energy sourcesExposure to special conditions that might affect the control of energy


GM Placard Standards

All placards must include:

Header

Graphic

Information grid

Awareness items


Placard Validation Process

A designated authorized person performs the step-by-step process of isolation and verification as identified on the placard.




If the procedure is determined complete and correct, the placard is posted along with the accompanying energy source tags or stickers.




If the procedure is determined complete and correct, the placard is posted along with the accompanying energy source tags or stickers.

If it cannot be validated that all energy sources are locked out and verified by the procedure, necessary actions are taken to correct the situation, and the process begins again.

Leadership ActionLeadership Action


Self-assessment Tool

The GMS Health & Safety Self-assessment Tool enables leaders to accurately measure facility’s health and safety management activities against specific criteria

Self-assessment is required annually

The Self-assessment tool is available on the Health and Safety web portal. A link is also provided in the Resource section of this presentation.


Self-assessment Tool


Criteria for “Green” Assessment

Procedures must be developed and available for workers prior to work performance.– The program should be reviewed annually– Workers must be trained

Plant follows a documented Lockout Energy Control program.



Lockout inspections must include interviews to assess employee knowledge of policies and procedures.

Interviews must be documented.

The plant audits the employees whose work involves Lockout/Energy Control annually to verify that they understand proper procedure.



Inspection will include::– The required task– Specifically-designated energy control procedures– Proper use of energy-isolating devices, when required– Proper application of locks by each authorized person, when

required– Deviations from established plant lockout energy control policy or

procedures– Validity of posted lockout placards

Plant reviews its Lockout/Energy Control inspection process annually.



Placards must be validated by an authorized person to determine if the procedure is complete and correct.

The plant audits its Lockout/Energy Control placards annually and updates them as required.



Lockout identification labels must be:– Durable– Standardized– Identifiable– Substantial

All Lockout/Energy Control points are clearly marked.



Placards must include all required information and be validated

Proper Lockout/Energy Control placards are posted where needed.



All Authorized and Competent Persons must be trained to recognize hazardous energy and the understand methods required to isolate and control the energy

All employees whose work involves Lockout/Energy Control and their direct supervisors are properly trained.



Each employee is provided a common personal lock to be used to lock out energy sources in accordance with the program – “One person – one lock – one key.”

Only safety locks and other lockout devices that meet the General Motors requirements are used to isolate energy sources.

Knowledge CheckKnowledge Check


A plant must review the inspection audit process once every two years.

True False

Click the button next to the correct answer choice.

Assess Your Knowledge


The plant must review its Lockout/Energy Control inspection process annually to meet the assessment criteria.

Correct Choice!


Wrong choice, the answer is False

The plant must review its Lockout/Energy Control inspection process annually to meet the assessment criteria.



What are the three (3) defined roles for personnel in lockout implementation?

a)

b)

c)

d)

Affected Person, Authorized Person and Competent Person

Competent Person, Safety Engineer and Supervisor

Affected Person, Authorized Person and Supervisor

Supervisor, Safety Manager and Engineer



Correct Choice!

The three types of personnel involved in lockout implementation are the Affected Person, Authorized Person and Competent Person.


Wrong choice. The answer is a.

The three types of personnel involved in lockout implementation are the Affected Person, Authorized Person and Competent Person.


A Lockout control program should not include:

a)

b)

c)

d)

Description of all placards

Purpose of the procedure

Sequence of the lockout procedure

Lockout removal procedure




Correct Choice!

A Lockout control program should include the following:Facility Lockout Procedure


Training





A Lockout control program should include the following:Facility Lockout Procedure


Training




Wrong choice. The answer is a.


Which of the following is not a type of energy considered for lockout energy control?

a)

b)

c)

d)

Electrical

Gravity

Chemical

Pneumatic




Correct Choice!

The types of energy areElectrical EnergyHydraulic EnergyPneumatic EnergyGravityStored Mechanical Energy, including MomentumMultiple Energy SystemsSpecial Energy Systems


The types of energy areElectrical EnergyHydraulic EnergyPneumatic EnergyGravityStored Mechanical Energy, including MomentumMultiple Energy SystemsSpecial Energy Systems

Wrong choice. The answer is c.


A maintenance worker has determined that a piece of equipment must be energized during a servicing task. Should the worker notify the supervisor?

Yes No




Correct Choice!

The supervisor should be notified if:

The machinery or equipment does not have adequate energy control devices for lockout

The machine or equipment must be energized during the maintenance or servicing task and workers may be exposed to a hazard


The supervisor should be notified if:

The machinery or equipment does not have adequate energy control devices for lockout

The machine or equipment must be energized during the maintenance or servicing task and workers may be exposed to a hazard

Wrong choice. The answer is Yes.

ResourcesResources


Resources

Subject Matter Expert• Global Lockout Resource / SME - Kyle Sullivan

[email protected]

Safetypedia• Located on the Health and Safety web portal

https://gmweb.gm.com/manufacturing/mfg_ghs/Safetypedia/index.htm

Web Resources• GMS Health & Safety Requirements

https://gmweb.gm.com/manufacturing/mfg_ghs/Pages/GMSHealthSafetyRequirements.aspx



http://sharepoint.gm.com/sites/hsn/Safetypedia1/index.htm

http://sharepoint.gm.com/sites/hsn/Safetypedia1/index.htm


Course Conclusion

This concludes the Lockout Energy Control Leadership Overview course. Thank you for your participation.

To receive credit for this course:

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Once inside the LMS, launch the assessment for Course #37848 (GMS Overview Lock Out Energy Control).

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Thank You


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