The challenges of lockout

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Mario Saucier, Eng. President of Groupe ID

Am I acting according to the law?

The first lockout challenge, for any employer in Quebec, is to ensure that he meets all legal requirements whether it is clause 51 of LSST or clause 185 of RSST. In addition, the CSA Z460-05 standard is the guide to use for implementation of a lockout system.

Lockout, do I believe in it?

You have probably heard comments like “It’s too complicated. Not another thing to do. It’s important but we have to maintain the production. I am too busy. The CSST did not say anything about that.”, and so on. However, the company must believe in it because it demands it, the Director must also believe in it because he authorizes it, the foreman schedules it and the employees apply it. So, if everyone believes in it, what’s the problem?

Lockout, does it concern me?

YES, YES and YES. Lockout concerns everyone: employees and directors alike. Everyone must be familiar with the role he has to play with respect to lockout system.

Lockout, why is it still a problem?

Beyond the requirements, the will of the persons and the responsibilities they are ready to take, several factors explain the difficulties to implement a functional system:

■ Implementation effort is significant and underestimated.
■ Resources required for implementation are not available.
■ Facilities are not in conformity with established practice.
■ Lockout is assigned to a champion. If something happens to him, the lockout is no longer used.
■ Operating rules are not clear.
■ Start-up tests are difficult to perform because of the level of automation.
■ There is a strong resistance to change.
■ Management tool is poor and there is a loss of data integrity.
■ Follow-up after implantation is ineffective or nonexistent.
 

What is the solution?

The method to follow is to support the organization in the different stages such as the analysis, the implementation and the optimization in order to integrate a functional system to the production and business processes.

The analysis allows to take a good picture of the situation, to identify the needs, to establish the goals and to determine the scope, cost and schedule.

The implementation is performed by following a reliable methodology which ensures the implementation of all elements of the system in the most functional possible way. It must be done by assigning the right resources and meeting the adopted deadlines  budget.

Once installed, the management system must be optimized and adapted to the changing needs of the organization to ensure that it remains functional. By doing an ongoing follow-up of the investment, the organization will ensure that benefits will be converted into a competitive advantage.

How can I be sure to succeed?

The lockout system must live and grow with the organization. For this, it must be integrated to other occupational health and safety management systems which also have to be integrated to the management systems of the organization as required by the CSA Z1000-06 standard. Thus, it is essential that the roles and responsibilities are defined in details and distributed to the most effective people.

Lockout, what do I get out of it?

A functional lockout system will have impacts on many aspects of the organization. The use of a computerized management tool will increase productivity concerning:

■ Creation of lockout procedures.
■ Work preparation and research for lockout procedures.
■ Preparing scheduled shutdowns.
■  Strat-up after scheduled work and shutdowns.
■ System management.

A functional system will have positive impacts on:

■ Employees: particularly employee recruitment and retention, quality of life, satisfaction, motivation, expertise backup, integration and staff training.
■ Costs: by reducing accidents and their severity, job stress, loss of time during the lockout and the risk of prosecution for not acting by due care.
■ Image: by enhancing the corporate image for employees, regulatory bodies, shareholders and the public.

Lockout, does it have an end?

NO, NO and NO. Changes made to the machines and facilities, purchase of new equipment, hiring new employees, continuing compliance with laws and standards, visit from CSST inspectors are the main reasons why the lockout system must be integrated with your organization to remain functional.

www.legroupeid.com 

The implementation of a functional lockout program

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Integrated security processes

Mario Saucier, Eng. President of Groupe ID

Regulation and standards

Several means can be implemented to ensure the safety of people within an organization. In Quebec, the regulations (RSST, art. 185),  says that before undertaking any maintenance, repair or unblocking into the danger zone of a machine … the lockout program must be applied for each person exposed to danger, for all energy sources of the machine, so as to prevent accidental starting of the machine during the work period.
To get to meet this requirement, employers must establish a lockout program. To this end, the sandard CSA Z460-05 is the guide to use. This standard specifies that employers must establish a written lockout program and one of the important elements of this program is the development of specific lockout procedures for each machine. Also according to the standard, the program must describe the sequence in which procedures must be implemented.

The effectiveness of lockout program

When a lockout procedure is used and applied correctly, it is very effective in reducing risk and protecting people as it aims to control all sources of energy from a machine. But because it is an approach, a method of work, people do not always think to use it and if they do, use it correctly.

So how can we arrive to make more efficient, in terms of the security and the risk reduction, the application of the lockout program? A lockout program, but?

The solution is to set up a program written in accordance with CSA Z460-05. However, to ensure the achievement of results and the continuance of such a program, it is essential that the standard be integrated into production processes and business of the organization. It should not be that the lockout program is the mere fact of a “champion” that supports it at arm’s length. If this is the case, our experience shows, inevitably, the program will die if the champion leaves the organization.

Beyond the requirements of the standard, elements of the lockout program need to be functional to ensure its success and improve the safety of installations.

We just have to think about these following aspects :

  • How can we assure the update procedure?
  • How to train staff? Who has to be formed?
  • How to transmit procedures to ensure their use?
  • How to facilitate the procedures application?
  • How to organize the system of lockout and accessories required?
  • How to evaluate the program and identify the areas that has to be improved?

What to do

According to our experience of over 20 years, To integrate its production process and business, Groupe ID is convinced that the support of the organisation in the stages of analysis, implementation and optimization of a functional program is what to do.

The analysis to be familiar with the current situation prevails, identify needs, establish goals and determine the scope, cost and schedule. At this stage the program is developed writing. It should cover the legal requirements and standards, roles and responsibilities, equipment and accessories required, the application process, special situations, training and program review.

The implementation is done by following a proven methodology that ensures the implementation of all elements of the program but the most functional as possible. This solution will thus have a positive impact on employee awareness of their roles, their active participation in the program and, ultimately, the number of accidents.

Once implanted, the management program should be optimized and adapted to the changing needs of the business to ensure it remains functional. It is by optimizing the company will ensure a return on investment that will be converted into a competitive advantage. All the resources invested, whether human or financial resources, helping to differentiate the company from its competitors.

The challenge

Like any other program, the lockout is no exception to the rule: the challenge lies not only in the establishment but also and especially in the evaluation and monitoring. The use of a specialized management tool will provide updates and data integrity lockout procedures to reflect accurately the facilities.

The Groupe ID commitment is to plan the investment required to integrate a functional solution for the management of the lockout system that will increase performance and profitability of the organization.

 

Groupe ID

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Intégration harmonisée de la sécurité

Pour ce faire, les experts de Groupe ID supportent les entreprises clientes pour tous les aspects distinctifs de leur offre, selon les besoins spécifiques à chacune. Les services offerts comprennent, notamment :

  • Le cadenassage :Un moyen de prévention qui neutralise les sources de danger avant une intervention sur un équipement, tel que l’entretien ou des réparations.
  • La gestion des permis de travail :permet d’assurer la mise en place des mesures préventives lors de la réalisation de tâches à risques élevés : soudage, meulage, coupage, travail en hauteur, travail en espace clos et plus encore.
  • Analyse du risque :Une analyse approfondie des équipements et des méthodes de travail permet d’instaurer des solutions de réduction du risque, qu’il s’agisse d’installer des protecteurs, des dispositifs de sécurité ou simplement de définir les habitudes de travail à adopter.
  • Système d’audit :Des audits périodiques sont nécessaires pour valider que toutes les mesures de sécurité soient respectées par les employés dans le cadre de leur travail et que les installations soient conformes.
  • Formation : À toutes les étapes du processus, l’accent est mis sur la formation du personnel tant au niveau du programme de gestion que pour la suite logicielle CONFORMiT®.
  • La suite logicielle CONFORMiT®, reconnue comme la plus avancée dans le marché, permet l’ensemble de la mise en place et de gestion du programme de sécurité des machines dans une entreprise de façon performante et à peu de coûts de tous les aspects essentiels des applications requises.