Text For Citation: 02 Item/Group: 001 Hazard: LOCKOUT

Section 5(a)(1) of the Occupational Safety and Health Act of 1970: The employer did not furnish employment and a place of employment which were free from recognized hazards that were causing or likely to cause death or serious physical harm to employees in that production employees were exposed to the hazards of being caught in and crushed by unintended accidental, and sudden activation of machines and machinery such as: a) Building G-36-R, Department 2651, "Bucket Line", the Cyboteck automatically controlled roboter welder; b) Building G-17-V, Department 2679, "Bevel and Form", CY120 1000 Flame cut Robot, machine M5808; c) Building G-45-54-E, Department 2652, "Engine Frame Machine and Weld", Moline tape controlled multi-station milling and boring machine complex, machines M3881, m3882, M3883, M3884; d) Building G-7-L, Department 2605, "Upper Frame", Cincinnati Milicron automatically controlled robotic welder; e) Building G-26-M, Department 2622, "Engine Frame Weld and Machine", Giddings and Lewis computer-controlled multi-station machining complex; f) Building G-45-T, Department 2685, "Loader Frames Weld and Machine", Kearney and Trecker electronically controlled 8-station multi- turreted loader frame machining complex; g) Building K-16-B, Department 2908, parts washer and dryer automated complex. Among other methods, one feasible and acceptable method to reduce these hazards is to enforce an adequate plant lockout procedure such as that stipulated by ANSI Z244.1-1982, American National Standard of Minimum Safety Requirements for Lock-out/Tagout of Energy Source of Personnel Protection. Essential elements of the lockout procedure would include: 1) Establish a comprehensive written procedure for lock-out which includes procedures designed to instruct and train employees in recognition of hazards and proper lock-out procedures. 2) Require lock-out before any maintenance, inspection, clearing, adjusting or servicing that requires employees to enter or be in close contact with machinery or equipment. 3) Maintain available operation and maintenance manuals on all machinery or equipment. Assure that these manuals and other appropriate information are provided to employees before work is begun. 4) Establish and use a documented work order system which includes supervisors' approval to reactivate machinery or equipment. 5) Disconnect or isolate machinery or equipment by positioning the switch, valve or other energy isolating device so that all energy sources (e.g. electrical, mechanical, hydraulic, etc.) are de- activated. Stored energy such as that in capacitors, springs, elevated machine members, rotating flywheels, hydraulic systems and gas, air, steam or water pressure, etc. must be dissipated or restrained by methods sush as grounding, repositioning, blocking, bleeding down, etc. 6) Require that each exposed employee lock-out the energy isolating device wich his/her personal lock. 7) Test machinery or equipment to ensure that the energy sources have been effectively disconnected or isolated. As a precautionary measure, return the operating controls to the "OFF" position after the test has been completed. NOTE: The Test shall only be performed after ensuring that no employees are exposed in the machine or equipment area. 8) Remove locks only after ensuring the safety of all exposed employees. 9) Train employees responsible for machinery or equipment lock-out in all elements of the program. This training shall be repeated as frequently as necessary to maintain management and work proficiency and compliance with the procedure. 10) Evaluate the program periodically to ensure continued use and adequacy. 11) Enforce all provisions of the program.