How crucial is Padlock and Tag during Lockout Tagout

Lockout Tagout are systematic safety procedures which control unexpected release of hazardous energy thus preventing industrial accidents from happening. An essential part of every Lockout Tagout procedures are safety padlocks and tags.

LOTO padlocks are energy-isolating devices that help in the implementation and maintenance of the OSHA-compliant Safety Lockout Tagout Program. Safety padlocks are used to lock off a specific piece of equipment or machinery, or even an entire region, during preventative maintenance or repair. Each employee is required to attach his own lock to the LOTO device to ensure maximum protection.  Whereas Safety tags are informative signs which indicate who is authorised to carry out any repair or maintenance work on the locked-out machine or equipment. The size and shape of tags vary based on application and usage including danger, warning, caution and notice display messages.

Safety padlocks and tags are used in unison along with other Lockout devices to protect employees from the release of hazardous energy. These are an intermediate element of a LOTO procedure as they are applied to another Lockout device when it is installed on the machine. These locking devices (padlocks and tags) may be used for valves, electrical or pneumatic equipment, gas components, etc. They are basic security devices that, when used in conjunction with a successful lockout programme, guarantee that all devices and equipment remain where they should be, with no unauthorised access conceivable. 

Safety padlocks and tags serve as both a visual reminder and physical lock to prevent accidental use of machinery during maintenance. In many facilities, they are also used to restrict access to the maintenance area where the work is being performed. A high-quality safety padlock can be difficult to get past without using excessive force and are more effective in securing the machines than merely a tag or employee notification. Padlocks are an important part of a firm’s industrial safety measures-particularly in areas where energized electrical equipment is present and the threat of arc flash accidents is prevalent. Lockout locks with one key per lock gives the sole authority of the machine and energy sources to the authorised employee. When effective Lockout Tagout procedures are followed along with application of safety Padlocks and warning Tags then the machine cannot be energised by any means. When padlocks are equipped with tags, they not only provide a physical barrier but also relay important information about the maintenance process like the duration of maintenance, authorised employee, reason for lockout, etc. In situations where there is no provision for Lockout devices in the machine, Lockout tags are the most effective way of securing the machines. Colour coded padlocks and tags according department, employee usage or machine location helps the facility in being organised, thereby increasing the effectiveness of your Safety Lockout program.

For successful safety procedures, Padlocks and Tags need to follow OSHA mandated requirements, i.e. they need to be -

1. Durable - Manufactured with materials that withstand usage environment

2. Substantial - Cannot be removed without considerable force

3. Standardized - Clearly differentiated from other devices by color, shape or size

4. Identifiable - Indicates the authorized employee that applied the device

5. Exclusive for Safety - Not to be used for purposes other than controlling energy

6. Attached to prevent operation of the disconnecting means without resorting to undue force or the use of tools.

7. The key or combination shall remain in the possession of the individual installing the lock or the person in charge, when provided by the established procedure.

Every industry can get their facility surveyed from experts to analyse risks associated with their equipment and create a comprehensive Lockout Tagout program along with high-quality LOTO devices. It is important for every industry to understand the importance of well-detailed safety measures which protect workers from avoidable accidents.

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