Lock out tag out Machinery Safety Risk Assessment Checklist

The safety of machinery is usually protected by guarding and separation of operators and maintenance personal fro

There have been a number of accidents in Unilever resulting from a failure to adequately assess the risks of stored

This guidance is supplementary to the exisiting standards and LOTO guidance. Its aim is to highlight some of comm
and maintenance personal from dangerous moving parts. However, during maintenance or unblocking operations there is often

ely assess the risks of stored or supplied energy.

is to highlight some of common short falls in LOTO risk assessments which result in all energy sources not being made safe.
perations there is often a need to work within guards. Before working on unguarded machinery suitable isolation of energy (LO

not being made safe.

isolation of energy (LOTO) must be in place.
 LOTO - Audit Checklist Summary
Y N N/A

1 Is there a Machinery Safety Sub-Committee on site? Y

Have all the machines had a safety risk assessment

2
and all findings been properly categorized (H/M/L)? Y

Do you have the CAPEX approved to solve the High

3
and Medium risks which have been identified so far? Y

Are the machinery safety risks and the respective

LOT 4
CAPEX reviewed periodically? Y
O
Gov
ern Is there a specific LOTO procedure/instruction for each
anc equipment? If partially yes, then specify the total
5
equipment (#) and the LOTO procedures/instructions N
e
available (#) in the comments area below.

Do the procedures identify all forms of hazardous

6
energy that need to be controlled? Y

Do the procedures identify how to release the stored

7 energy from all energy sources and prevent Y
accumulation?

Has the site established a formal Deep Compliance

Audit (DCA) process for LOTO to check the integrity of
8
implementation and established an action tracking Y
process for the gaps found?

9 Is there adequate number of locks and tags on site? Y

Are there appropriate LOTO devices available for each

type of hazardous energy to be controlled? (e.g. hasps,
air regulator lockout devices, ball valves lockout devices Y
10
etc.)

Based on incidents happened on site or other sites, is

the site evaluating the respective Lessons Learnt,
identifying common risks and plan similar corrective and Y
11
preventive actions?
 LOTO - Audit Checklist Summary
Y N N/A

Has a targeted training been provided to every

individual (appropriate to role and job level) involved in
12
LOTO, to ensure that the purpose and requirements of Y
the LOTO procedures are understood and followed?

Is there a defined process to evaluate training

13
effectiveness? N
LOT
O
Is the frequency of training stated in the relevant LOTO
Trai 14
Training Procedure? N
nin
g Is there a process to validate the knowledge of LOTO in
15
supervisors/line managers? N

Is there a process to validate the knowledge of LOTO in

16
operators? Y

Is there a process to validate the knowledge of LOTO in

17
contractors? Y

Has the site identified and understood all electrical

18
energy sources? Y
Is there a lockable isolation switch (multiple where
19
needed) in every machine that isolates all electrical Y

If the answer in the question above is ''NO'', is the

Ele removal of supply fuses and the locking of the fuse box
ctri 20 required according to the local LOTO procedure for the NA
cal particular machine? If the answer in the question above
Ene is "YES", you can answer this question using "NA".
rgy
Has the site identified secondary power sources that
21
exist after applying LOTO? Y
Is there a written statement in the site's procedures to
22 indicate that the use of e-stops for the isolation of Y
electrical power is not acceptable?

Has the site identified and understood all pneumatic

23
energy sources? Y

Is the isolation and depressurisation of pneumatic

24 supplies carried out to move the machine to a safe Y
state?

Pne If pneumatic supplies cannot be isolated, is that stored

um 25 pneumatic energy identified and suitable Y
atic alternative/additional mechanical locking devices used?
ene
rgy Is the absence of pneumatic energy verified by
attempting to operate the associated components and
26
by observing the associated gauges to ensure they Y
indicate no pressure?

Generally, pneumatic isolation devices automatically

vent air pressure when lock out occurs. Has the site
27 identified machine(s) that require manual venting and is Y
this manual action clearly stated in the respective
procedure(s)?
 LOTO - Audit Checklist Summary
Y N N/A

Do lockout procedures take in consideration all forms of

stored energy? This could be from (the list is not
exhaustive):
28
- compressed springs N
- weight held at height
- off balance weights that can rotate

Mec Where there is not positive locking of mechanical

han energy as part of machine design (e.g. automatic
ical locking pins that fail to a locked position), then is
Ene alternative positive locking of devices used before
rgy 29 machinery is accessed? Suitable means of isolation N
include:
- additional jacks or scaffolds,
- lock and chain devices or
- spring clamps.
Does the site has a process to review the need for
positive isolation where the removal of other devices
30
can result in movement of weights (e.g. removal of drive N
chains or securing bolts)?

The
rma Ensure heat is dissipated in the safe manner as defined
l 31 by the site: Has the site defined a waiting period until Y
Haz the desired working temperature is reached?
ard

Gra
Has all equipment subject to gravity been properly
vita
restrained during operating in the area and/or
tion
al
32 positioned in manner that gravity cannot cause motion? N
Various supports, blocks, pins or bottoming out the
Haz
equipment are some methods to accomplish this.
ard

Does your factory have any sigma mixers (or Z blade

mixers) in operation? If the answer is ''Yes'', please
33
indicate the quantity (how many mixers) in the Y
comments section.
Has the frequency of an internal and/or external LOTO
LOT 34 audit been established? Y
O
Aud
it Has a 3P audit, done in the last 3 years, covered
35 Y
LOTO?

Have all findings been given priority and plans

36 Y
developed to close the action items?
Action for site/ Explanatory Guideline

Risk Assesment SC to be renamed as RA & Machinery Safety subcommitte.FM to send a mail to site team informing about the change.
Please mention in the mail that the subcommitte's scope will include
1. Action on Safety Risk Assessment of any new machinery added/modified
2. Review of Safety Risk Assessment of existing machinery basis site incidents/NM/SAM; LL received
3. Deployment of LOTO Procedures, LOTO Training, Capability Assessment and ongoing retraining
4. Resource suport to provide and maintain LOTO and Machine Guarding facilities appropriate to identified Risks
5. Ensuring compliance to LOTO and Machinery Safety DCA, Action tracking for the gaps found during such DCAs
6. Any and all actions required to ensure site's compliance to applicable Unilever Machinery & LOTO Standards

Typical Response --Yes; Typical Comment: Done for all existing machines and whatever findings emerged have been properly categoried.
Exception-- see below
It is only asking whether safety risk assessment has been done for all machines and whatever findings emerged, those have been properly
categorized. This answer should be yes, unless your site has got machines in operation which have not been risk-assessed. It is not saying
that the RA is perfect, just whether it has been done.

in general answer should be yes. It is just asking- have you got money to rectify the already known gaps.

in general answer should be yes. Reviewed in CRM in most factories

Site to review and answer as per the current status , the expectation is that all safety critical equipment must have LOTO procedure

Yes.Part of LOTO procedure

Yes.Part of LOTO procedure

In general, all sites would have covered LOTO in DCA. So this should be Yes. If missed out by some site, please include it immediately , refer
attached checklist as sample; feel free to improve now or later.

Please respond as the case may be at the site.

Actually it's a case of 'wanting to do LOTO'. In general, it is possible---if people want to do LOTO and that particular energy source can not be
isolated, then the next higher level source can be isolated, even if it means some additional equipment also going out of operation. We need
to prioritize safety. Barotiwala incident is a classic case--they did not have LOTO clasps suitable for isolation of individual MCB. So they opted
for a weak panel lock option and it failed.
But if they were risk-sensitive, they could have isolated the full panel, even if it meant two more soap lines getting stopped for 1 hour-- it was
just lucky that the fitter did not lose his hand.

Yes, LLs are usually evaluated in safety meetings (but often not recorded in MoMs),local language versions displayed in canteen and
shopfloor. Some progressive units also create AVs in local language with help of operators. It is suggested to have a mandatory discussion
on LL in every monthly safety meeting, which is then recorded in MoM
Action for site/ Explanatory Guideline

yes.Sites to maintain training records

LMS courses for FLT have in-built assesments. Evaluation/Assessment system for ALL safety trainings need to be put in place by June.
Category/Country Safety Managers will support sites.
Sites to include LOTO training frequency in their training calender.LOTO training procedure at site to have a training lecture followed by a
demonstration. this will be repeated every quarter.''

Sites can respond as follows in the comments section:

will be done by Q3 in consultation with Cluster Safety team.

as above

as above

same as 10 above.

same as 10 above.

LOTO procedure to be reviewed to include local battery/UPS backup , if not included

To be included if not there in the existing LOTO procedure/SOP

Review LOTO procedure and include - lock the inlet valve in closed condition and vent valve in open condition. Then only it will be full LOTO
of pneumatic energy. If there is no vent valve provided, please make a Mod-Note and install it -- vent to a safe location. a pressure gage may
also be installed at LOTO point to give confidence to the person performing LOTO that he has brought the system to safe state before he
puts his LOTO lock.

Revisit LOTO hardware and install pressure guages at the point of isolation

LOTO procedure for individual equipment to be reviewed to include manual depressurisation where required.
Action for site/ Explanatory Guideline

a typical comment for this question & the one below: While this has been done to the extent of team's understanding in existing RAs, it is
planned to carry out an exhaustive exercise in light of the gateway incident. This exercise will be completed in 1-2-3 (max) months.

as above

as above

safe working temperature is defined

same as 28-29-30 or as the case may be at the site

as the case may be

Internal LOTO DCA every month, External - cross site to start (annually)

as the case may be

as the case may be

Remark/Action

Need to rename RA Sub Com, Charter also need to

revise accordingly

Received Central Budget for Machine Guarding

In Capex review meeting

LOTO SOP is Available, Machine specific loto

procedure not available

LL Communication in Safety Meeting/SHE Com

Remark/Action

Plan to be made for core team employees and

contractors

LOTO LMS

Refresher training calender With Quarterly frequency

Will be done by Q3 in consultation with Cluster

Safety team.
Pre-Post Questnnair for Shopfloor & contractors
employee done

Pre-Post Questnnair for Shopfloor & contractors

employee done
Remark/Action

Equipment identified as per gateway Incident

Learning

Equipment identified as per gateway Incident

Learning

Equipment identified as per gateway Incident

Learning

Equipment identified as per gateway Incident

Learning

4 Sigma Mixer

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2015