PowerPoint Presentation

[Audio] Hi Namaste Desno Ten Uno Minda Welcomes you Today we will be learning about loto.

[Audio] But first… Why are you here? Because in Denso Ten Uno Minda your safety is our priority. And thus we encourage that you get trained properly on how to apply loto and do your activities safely As loto (Lockout/Tagout) prevents accidents by ensuring machines are safely de-energized during maintenance protecting workers from hazards..

[Audio] As we read loto (Lockout/Tagout) prevents accidents by ensuring machines are safely de-energized during maintenance protecting workers from hazards. Course Goals : After completing this course you should be able to: Explain what control of hazardous energy is when it is used and who is affected Describe the six-step process for lockout/tagout Identify loto locks tags and devices But Remember: To be authorized to perform loto you will also need to complete a hands-on demonstration.

[Audio] Toady we will be learning about: What is loto What is control of Hazardous Energy? What are steps of apply loto? What are the steps to remove loto? Special conditions where loto is exempted. And more….

[Audio] Now the big question….What IS loto? We can answer this in three simple ways: Number 1 loto is a method used to control hazardous energy during the servicing and/or maintenance of machines and equipment processes or circuits. Number 2 loto is designed to prevent injuries and damage caused by the unexpected activation of hazardous energies including any unintended motion energization startup or release of stored energies..

[Audio] Number 3 loto is the placement of a red lock and tag on the energy-isolating device in accordance with an established procedure indicating that the energy isolating device shall not be operated until removal of the red lock and tag in accordance with an established procedure..

[Audio] But… Why Do We Use Loto? Protect ourselves and our coworkers Ensure we are working with safe conditions Prevent the accidental startup or release of energy while working on a system Protects the equipment from damage Helps confirm our compliance with laws/regulations Helps us service and maintain equipment safely.

[Audio] Now let us discuss as where loto is required in our site: Servicing Maintaining Erecting Adjusting Cleaning Installing Unjamming Dismantling Constructing Setting Up Repairing Lubricating.

[Audio] Now let us discuss about what is the hazardous energy that pose a big threat while doing any routine or non – routine activity. In simple words hazardous energy is the energy stored within the equipment process or circuit that would need to be released before we can complete servicing or maintenance. Types of hazardous energy present in our unit are: Mechanical Electrical Hydraulic Pneumatic Chemical Radiation.

[Audio] As now we understand the risk the hazardous energy stored in an equipment or machine pose it's important to understand the most effective and correct way to apply loto. Let us understand How to apply loto.

[Audio] Psiacv This is a 6-step process to apply loto effectively and safely STEP 1 Prepare for Shutdown: Determine the types magnitude and hazards of energy entering and within the system. These include but are not limited to: electrical; hydraulic; pneumatic; gas/water/steam; mechanical (gravity kinetic); chemical/coolant; radiation; magnetic. All effected personnel will be notified. Anyone who may be involved in the use of the equipment or affected by the shutdown of the equipment shall be notified (for example machine operators). Step 2 Shutdown of Equipment/System: Follow normal procedure for shutting off equipment. Step3 Isolation of the Equipment All energy isolating devices that will be locked or tagged out will identify. Specific how each isolation device is operated (close valves open disconnect switches and circuit breakers blank lines unplug electrical cords). Step 4 Application of Energy Control (Lockout/Tagout) Devices Each energy isolating device shall be made inoperable by locking and tagging using an appropriate device: breaker lockout; electrical plug lockout; gate valve lockout; ball valve lockout adjustable cable lockout chains and approved loto locks. If the device cannot be effectively made inoperable consult Control of Hazardous Energy Program. Any additional measures that should be taken to demonstrate full employee protection such as the removal of an isolating circuit element blocking of a controlling switch opening of an extra disconnecting device or the removal of a valve handle to reduce the likelihood of inadvertent energization should be included in the procedure. Step 5 Control of Stored Energy Stored energy will be dissipated or restrained in a controlled fashion. Methods include but are not limited to: repositioning; blocking; bleeding down; discharging. All stored energy must be controlled. This included both initial removal of the energy and the prevention of 'recharging' of the energy. Step 6 Verification of Zero Energy State Prior to starting work the authorized employee will verify that isolation and de-energization have been accomplished. This step of the procedure may involve a deliberate attempt to start the equipment which has been isolated the use of appropriate test instruments or visual inspection. A combination of these verification methods may be needed; the appropriate method or combination of methods will depend upon the type of machinery or equipment involved the complexity of the system and other factors. NotE: After attempting to start the equipment ensure that operating control(s) are returned to a safe condition (for example 'neutral' or 'off') before proceeding with service or maintenance..

[Audio] You will notice for every letter of the six steps you will have one overview slide. In this slide we will take a higher-level view of what P (Prepare) means and understand that this is step 1. During prepare we want to make sure we have everything we need to begin work before we begin work. Being prepared to start the loto is going to set us up for success and make the process safer and more efficient. You will gather all the documentation and review a safe work plan job safety analysis (J-S-A--) and risk assessment. Review equipment specific loto procedure Determine the types magnitude and hazards of energy entering and within the system Control access in the area where loto is being applied and notify any affected individuals. Remember these are individuals that use to work on the piece of machine or in the process that will need to be removed from the area and not interfere or be part of the loto work activities. And last but very important gather all the required loto devices tools and PPEs..

[Audio] S is Shutdown. This is when we begin to shutdown the process or equipment. Meaning we are turning off the various energy sources that we have. For example we switch the machine from on to off or we power down a piece of machine at the access panel from on to off. Also we may need to turn a valve to stop the flow of liquid or chemicals to a machine or process. Remember! just using the E-Stop is not a means of stopping the flow of energy to a part of a machine. It is a temporary disconnect of energy but energy is typically still flowing (but a belt or machine may not be moving). Typically a machine will have an on and off process and not rely on the user hitting an e-stop to shut it down. Many times hitting an e-stop can affect the machines operation or quality..

[Audio] I (Isolate) this is our first step of isolating our energy from their sources. We refer back to P (Prepare) on this step thinking about each of those isolation points and how to isolate each one. Separating the equipment from external energy sources. must know all energy sources Identify All energy isolating devices that will be locked or tagged out. Specify how each isolation device is operated (close valves open disconnect switches and circuit breakers blank lines unplug electrical cords)..

[Audio] A – Apply – Now we are going to ensure those isolating devices are applied and makes the point inoperable. We are going to make sure we use the appropriate device and then our red lock and tag..

[Audio] C-Control of stored energy After the equipment has been shut down isolated from external energy courses and lock out/tagged out we need to release any leftover (stored) energy that is within the equipment or process. Stored energy such as motion pressure gravity electrical or temperature is a potential hazard that still exists after a primary energy source has been locked or tagged out. All stored energy must be relieved dissipated restrained drained or otherwise controlled. Methods include but are not limited to: repositioning; blocking; bleeding down; discharging..

[Audio] V-Verify Zero Energy state A "Zero Energy State" must exist in the machine equipment process or circuit before servicing and/or maintenance activities can begin. The best method possible must be used to verify that energy has stopped released dissipated or drained completely. Verification provides certainty that energization cannot occur while work is being performed. It is very important that when we do our verification we have a clear understanding that the isolation is complete and does not pose any additional threat of energy release. In this section we will discuss further the try out portion. As always check and double check the system to ensure everything is in place and working as planned before beginning work..

[Audio] Now How to verify zero electrical energy: Manually Operate all Switches/Buttons; and make sure to return switches to "Off" position For exposed electrical test for voltage: Verification testing with instrumentation should be done by a Qualified Person; and make sure to check your testing equipment first. Ground when Appropriate. To verify zero pneumatic hydraulic thermal and chemical energy: Check your gauges but don't rely on them: you need to also check the block and bleed Check temperature with an independent device.

[Audio] Just like the loto process there are six basic steps for returning equipment to service. These steps are completed by Authorized Individuals. After the task has been completed here are the items we need to complete in order to return that equipment to service: First we need to ensure A-L-L employees are clear of the area of the equipment or process that will be turned back on. Even authorized individuals. Things can happen unexpectedly when turning equipment or processes back on after loto so its important no one is in the line of danger. Inspect the work area to ensure that non-essential items have been removed guards are in place the machine equipment process or circuit is operationally intact and move all personnel are to a safe location. After the area has been inspected and all personnel moved to a safe location the locks tags and lockout devices must be removed from each energy-isolating device so that the system can be reconnected to all energy sources..

[Audio] Once things are operationally ready to be turned on. We once again confirm no one is in the line of danger and moved to a safe location. We begin the process where each individual removes that lock and tag. Once the last person or loto supervisor in some cases is off the loto isolation point they confirm that area is clear and ready and that process continues for every isolation point. Once everyone is off the loto the isolation points can be reactivated until the equipment or process is back up and operational..

[Audio] Now What is the maximum permitted duration for a loto? The maximum permitted duration for a loto is one shift or the end of the task whichever is shorter. This does not mean the entire loto is over but the portion controlled by one individual. But What do we do if a task requires the equipment (or process or circuit) to be locked out/tagged out for more than one shift or what happens if there is a personnel change in the middle of a task? Remember there's one lock one tag one person..

[Audio] For the immediate hand-off of loto in-progress: Authorized individuals of the outgoing shift remove their Individual loto locks and red tags. Authorized individuals of the next shift simultaneously apply and secure their Individual loto Locks and red tags at the same energy-isolating device and verify that a zero-energy state exists in the system via the "tryout" process. Ravi's shift is from 7 to 3 he worked all day under a loto but the loto needs to continue because maintenance is not complete. Satyawan comes in at 2:30 and will continue the maintenance work. Ravi will stand at the loto isolation point with Satyawan he will take his off and Satyawan will immediately (or before if possible) put his lock and tag on. Maintaining continuity the entire times. Satyawan then needs to follow the same PSIACV process and focus on the V stage to verify..

[Audio] What if it is necessary to work on energized equipment? In other words what if complete loto cannot be used? Complete loto is always the first choice. We do not ever want to use alternative methods unless absolutely necessary. In very specific limited situations (which we will discuss in more detail on next slide) alternative energy control procedures providing equivalent protection to employees are required. Alternative methods are not allowed where loto is feasible and if the alternative methods are simply easier faster less complex or cheaper..

[Audio] The Alternative method is a true exception and not the rule. In all cases we should strive to use loto to the fullest extent. If we have to do any of the above tasks alternative methods are not allowed It can not be emphasized enough that alternative methods are only to be used in rare circumstances..

[Audio] This is a disclaimer slide. We want to remind the you that just because they took the loto class does not mean they are qualified to work under loto Y-E-T--. You still need to complete the exam with a 90% and need to do the loto demonstration and make sure they have the appropriate technical/competent knowledge on the equipment they are working on..

[Audio] Remember!! You are empowered to S-T-O-P Work when you or your coworkers feel unsafe You shall reach out to your direct manager customer contact or E-H-S at any time You shall engage and ask questions any time you are unsure of the operation or task that you doing.