Learning from lockout/tagout incidents

Following an increase in lockout/tagout incidents Bruche Associates is sharing some of our investigation findings.

Proper lockout/tagout procedures can help prevent serious injuries, but only if those procedures are followed.

“A lot of organisations have got the best procedures in place, but it’s the implementation of the procedures that fails,” Lee said.

Some of our investigation findings include:

• One employee had gone home for the day with his lock on, and the next worker on duty cut the lock off.
• Employees simply used a label on older equipment for which secure lockout was more difficult.
• Instead of installing a chain to lock a valve in place, a wire that could be easily cut was used.

Even if all lockout/tagout steps are followed, faulty equipment can still lead to failures. Lee recalled in a separate case at another workplace where an electrician doing rewiring work was shocked. The equipment was locked out, but the instruments he was using to check the system were faulty and failed to read that the system was live and not isolated. The worker touched a live cable, causing a full thickness burn.

Violation of lockout/tagout procedures often boils down to three reasons:

1. Complacency
2. A rush to finish the work
3. Being unfamiliar with the equipment

Employers need to train employees on lockout/tagout and ensure they’re qualified to carry out the procedure.

About Bruche Associates Limited

Bruche Associates are an established Health & Safety and Continual Improvement Consultancy, which evolved out of the chemical and oil and gas industries. Bruche Associates Limited is a family run business overseen by Lee and Joanne Marsh who have over 35 years combined experience working in Healthcare Medical Services, Health & Safety Management and Training and Development. Lee qualified as an Emergency Medical Technician (EMT) in 1996 before moving into Health and Safety Management with ICI Paints. We work across a range of sectors from chemical manufacturing, engineering, trade & retail, and small & medium size businesses