Why Your LOTO Program Is Failing and What to Fix First
Most plants audit LOTO compliance once a year and call it done. Meanwhile, lockout-related injuries keep climbing. Here's what's actually breaking in your program and how to catch it before OSHA does.
I walked a automotive fabrication shop in Michigan last month where the maintenance supervisor pulled a circuit breaker on a 400-ton hydraulic press, locked it, and tagged it. Standard procedure. I asked him to show me the energy isolation points. He pointed to the breaker. I asked about the pilot pressure lines feeding the hydraulic manifold. Silence. That press had three more energy sources he was not isolating. One equipment failure later, we were talking about a near-miss that could have killed someone.
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