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Compliant Lockout/Tagout Device Recommendations

From the Gobal Leaders in Engineered Safety Solutions
Facility worker in blue tshirt and yellow safety vest reviews lockout/tagout device recommendations on red and white diagnal striped tag with red triangle exclamation point in the middle below a black rectangle  covered by white oval and red oval hanging from cabinet door handle
Safety Solutions

As the global leader of lockout/tagout services, Rockwell Automation continuously tests new lockout devices to confirm they work and are user-friendly. Each lockout/tagout program completed by Rockwell Automation includes a list of recommended locks, devices, and lockout device stations.

Device recommendations are the final step in developing a lockout/tagout program. By purchasing the correct locks, tags and devices, you’ll benefit through improved efficiency of the lockout/tagout process. It also helps employees feel confident that when they apply lockout/tagout to the equipment, it remains securely locked out.

Our specialists stay informed about new product releases. Using their device insights and your customized lockout/tagout policies, they will provide best recommendations on the latest, most appropriate devices for your needs.

Lockout/Tagout Device Storage Solutions

Where to Keep Your Locks and Devices

For a lockout/tagout program to be effective, several key components must be established. One of these key components is having the necessary hardware for servicing activities. Locks and devices are the instruments for performing lockout, so overall accessibility of these tools is critical. Determining the best placement of these devices is the difference between an efficient lockout/tagout program and an inefficient one.

Often, this will determine whether employees will or will not use lockout when needed, and in the case of the latter, there is the possibility of needless near misses, injuries, or fatalities. So where is the most ideal place to keep lockout devices?

The number one recommendation when deciding where to place lockout device storage cabinets is to keep it easy and accessible. Many workers have complained that if it takes more than a few minutes to retrieve a simple lock and tag, they would rather skip the entire step and work on the equipment without proper lockout.

Fortunately, keeping lockout hardware within reach is a possible solution.

When the time comes, authorized employees can quickly notify operators and other personnel of the lockout being performed, and at the same time acquire the proper locks and devices after reviewing the lockout procedure. The less distance employees must walk from the machine to the lockout device storage, the more likely they will actually lock out the machine.

Depending on the layout of the facility, proper placement of the storage cabinets for maximum efficiency may vary. Some facilities have one main building, with large open space where all production lines run. Other facilities are compartmentalized, with each production line separated from one other. And still others are even more complicated, with maze-like layouts. 

Here are some recommended options for each situation:

For buildings where all production equipment is in one location

For small facilities, a single, centralized storage location may be ideal, such as a center pillar in the building. For larger facilities, it may be necessary to place a storage location for each area of production, for example one location for “Packaging Area,” one for “Mixing Area,” etc. If the layout contains multiple long lines of production, it may be best to have a station for each line. Other times it may be easiest to have a station in the middle of each wall so no matter what equipment is being worked on, devices will be close by.

For buildings divided into many sections and rooms, connected by a main hallway

If each section of the facility is connected by main corridors, an ideal location would be in those main corridors. Another option is to hang cabinets at the entrance to each room; by keeping placement consistent, employees will have an easier time locating devices from area to area.

For facilities with no patterned structure or main hallway

For layouts like this, it may be trickier to maintain consistent placement of storage boxes, but it’s not impossible. Try to divide the building into reasonably sized sections for a starting point. Afterwards, find a centralized spot in each area that is open and not crowded by equipment and machinery. This will ensure that lockout stations are easy to spot and easily accessible. Try to keep equal spacing between stations.

For rooftop equipment such as air handling units and exhaust fans

An option would be to place a lockout station at the main entrance to the roof. Since workers will use the main entrance to access the equipment, giving them access to locks and devices at the same time is ideal. Outdoor storage is typically not recommended due to weather conditions, but for warmer climates, it may be an option.

For facilities varying in all applications

As long as the company is willing to provide devices for all authorized employees, they can provide all authorized individuals with a personal device kit to carry while performing machine service work.

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