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What could we do next?

Well… we said we were always thinking to address gaps and make better products….

The key question uppermost on our mind was – how could we improve the LOTO padlock further?

On a field assessment in Dubai, our customer asked us a simple question… how does one define the sequence of applying and removing padlocks in a LOTO Program.

Padlocks application and removal sequence is generally defined in a PTW but there was no way to physically define this in a padlock itself. That was our eureka moment right then.

Multiple locks are generally applied with the use of a scissor hasp, once applied all locks become equal and does not indicate who applied the first or last lock.

The next few weeks were invested on the drawing board and looking at the padlock for long hours. It finally dawned on us that we could actually revamp the design to include features which could physically determine the application and removal sequence.

TEAM-LOK™ was born 2 months later after several 3D prototypes were generated to check the feasibility and features would hold upto the rigors of internal & external LOTO programs under extreme weather and working conditions.

2 versions have been developed – the TLH-1 model with a single loop to accommodate an additional secondary padlock and the TLH-3 model accommodates 3 secondary padlocks.

How TEAM-LOK™ works:

PATENTS:

The innovative design has resulted in utility and innovation patents being granted in USA, UK, Netherlands, Australia, India, China and pending in UAE, KSA & other countries.

CURRENT SCENARIO

CURRENT SCENARIO… SCISSOR HASPS

PTW’s define procedural hierarchies for locking / unlocking of energy isolation points. The challenge has always been to convert this sequence into a physical and visible system of First In–Last Out & Last In–First Out (FILO / LIFO).
The traditional system of Group Locking involves Scissor Hasps with multi padlocking facility where all locks are equal without any distinct hierarchy of the locking and unlocking sequence.
Individual padlocks can be removed without supervision which can lead to unsafe act / condition.

PROBLEM SOLVED

TEAM-LOK™ is the ONLY Safety Lockout Padlock that converts a Procedural Hierarchy following the FILO / LIFO system of locking and unlocking.

TEAM-LOK’s patented design allows 3 secondary padlocks OR multiples of Primary Team-Lok’s (TLH-3) + secondary padlocks to be inserted into the attachment effectively blocking the key access of the Primary TEAM-LOK™ safety padlock.

This action ensures a proper locking and unlocking sequence in line with Lockout / Tagout procedures.

* The author of this blog is Qaid Zohar – Director at LOTO Safety, Dubai.
This blog is written to educate interested parties on Lockout Tagout products.

LOTO BLOG – 6

The ubiquitous plastic padlock used for immobilizing a wide range of energy sources in lockout tagout programs has come a long way in 30 years from the date when OSHA enforced energy isolation guidelines on industry to prevent injuries and fatalities in the workplace.

The metamorphosis of the LOTO padlock over the past few years has led to several additional features being inculcated along with a higher degree of tamper resistance and traceability by various manufacturers.

CONSIDER THIS:

1. For over 2 decades, the market was dominated by 2 American brands who made plastic padlocks which had little or no information other than a number lasered on the key.
2. Additional features viz: individual names, logos and key number engraving on padlock body were customized at additional costs to be incurred by the buyer.
3. The key system of the padlock, ie: Keyed Different OR Keyed Alike OR Master Keyed was generally recorded in the system but did not appear anywhere on the padlock. In the event of key loss or misplacement informed decisions could not be made on whether the lock had to be destroyed or if a spare key was available.
4. Padlock covers to protect dust, dew and grit ingress were available as an additional product from some manufacturers.

THE 3PTP STORY:

As a relative newbie in the LOTO scene in 2011, we were always brainstorming on how we could add value and address gaps to provide additional features out-of-the-box to save downtime on tracing keys to locks, knowing the key system without having to refer to documents as well as retrieving keys quickly from cabinets to open locks during the re-energization process.

The 3 Point Traceability Padlock (3PTP) was born from various inputs derived from end user interactions.

The features we inculcated into the padlock helped save substantial downtime and increased the life of the padlock with it’s weather protection features.

1. Key system molded on body and one side of key – KD (Keyed Different), KA (Keyed Alike), KD+MK (Keyed Different + Master Keyed).
2. Key number lasered on padlock body and key enabling quick key to lock tracing.
3. Key jacket matching padlock color resulted in saving substantial downtime when tracing keys from cabinets.
4. A sliding key cover which prevented dust, grime, dew and grit ingress into the cylinder.
5. 2 additional rubber bushes which if needed could be installed on the shackle to prevent ingress into the plastic body of the padlock.

SUCCESS LIES IN THINKING FROM THE CUSTOMER VIEWPOINT:

The patented 3PTP padlocks were launched in 2012 and over time ended up establishing the gold standard for energy isolation padlocks. The popularity increased over time leading to most customers specifying the 3PTP features as a minimum standard for their LOTO programs thereby forcing the competition to comply.

Not content to rest on our laurels, we kept working on improvements to make a more aesthetic + higher tamper resistance padlock.

REVAMPING THE 3PTP OVER A DECADE:

1. Steel chrome plated shackle changed to SS304 to prevent corrosion in chemical / saline atmospheres.
2. Normal plastic non-conductive shackle re-engineered with a stainless steel metal insert. The 3PTP had a 5.0mm shackle diameter as standard which was more susceptible to breaking than the standard 6.0mm version on other brands. To enhance the cut / break resistance, we inserted a SS304 metal rod internally and molded over with a hard bearing PA6 nylon end to end.
3. Colors were revamped from slightly darkish to a more brighter range thereby increasing visibility.
4. The individual box packing was redesigned with a transparent window allowing color and key number visibility without having to remove the padlock.

* The author of this blog is Qaid Zohar – Director at LOTO Safety, Dubai.
This blog is written to educate interested parties on Lockout Tagout products.

LOTO BLOG – 4

The focus of this topic is to discuss the most important part of the energy isolation program – the physical implementation of Lockout / Tagout devices and the vast number of hardware choices available? How does one choose the correct device if sufficient information or knowledge is not available on hand?

Companies implementing the LOTO program for the first time find it difficult to select the correct devices and padlocks without professional help. We have been witness to many companies ordering individual products and Loto Kits from catalogs based on the assumption that they are purchasing a “One-Fits-All” solution. Nothing could be further from the truth.

“Universal Type Device” is a typical terminology used by some manufacturers to portray a device which fits on a wide range of energy sources – as in the case of “Universal” circuit breaker lockout device or “Universal” valve lockout device. This beguiling term psychologically induces the end user to believe in the “One-Fits-All” solution until the myth is shattered when the LOTO device is found unsuitable for that particular energy source.

LOTO Safety disseminates knowledge by providing free on-site assessments in the UAE coupled with training personnel on the correct application and compatibility of LOTO devices for different energy sources – all without any pecuniary benefit as well as a No obligation to buy policy. Our mission is to educate and inform without pressurizing the customer to purchase their LOTO hardware from us.

Customers out of UAE can register on our website and access our library of LOTO installation images for different types of energy sources be it electrical or mechanical. We are confident this would address 70 – 90% of their requirements.

https://www.lotosafetyproducts.com/my-account/

Free online advice is also available from us – simply mail or WhatsApp the images of the energy sources and we will identify and inform the most suitable devices.

The lesson we took away over the past decade is that it isn’t necessary to sell more, rather it’s imperative to view oneself as an extension of our customer. Our continued success is based on this founding pillar.

* The author of this blog is Qaid Zohar – Director at LOTO Safety, Dubai. This blog is
written to educate interested parties on Lockout Tagout products.

When maintenance or servicing work is being performed by more than one Authorized Employee, a Primary Authorized Employee must be assigned responsibility for controlling all energy isolating devices for the machine, equipment or process.

• Before beginning work, the Primary Authorized Employee will implement a specifically written energy control procedure developed for the particular energy source/s. He then isolates single or multiple energy sources by applying padlocks and verifies the machine, equipment or process has been isolated and Locked Out. The Primary Authorized Employee secures the key/s of the locks in the Group Lock box and applies his personal lock to the box.
• Other Authorized Employees review the adequacy of the isolation and apply their own locks to the Group Lock box.
• Authorized Employees perform work.
• Upon completion of work, each Authorized Employee removes their own personal lock(s) from the Group Lock box.
• The Primary Authorized Employee is the last one to remove his lock from the group lock box to access the keys for unlocking the energy sources. This can only be done after the Primary Authorized Employee has assessed the area and is satisfied it is safe to do so.

• Complete equipment specific LOTO Procedures.
• Conduct annual & periodic inspections.
• Keep a list of authorized employees.
• Issue LOTO devices to employees.
• Ensure all affected employees are properly trained on LOTO procedures.
• Enforce compliance with LOTO program.
• Provide employees with copies of the LOTO
• Program upon request.

• Recognizes hazardous energy.
• Types and magnitude of energy in the workplace.
• Means to isolate those types of energy.
• Repair or service equipment as needed.
• Ensure that all energy sources are locked out.
• Test equipment to verify residual energy is dissipated.
• Place a “Danger-Do Not Operate” tag on equipment.
• Obtain assistance when necessary.
• Remove locks and/or tags following LOTO.
• Coordinate multi-shift repair.

Affected Employees Responsibilities

• Employees who operate equipment.
• Work around.
• Occasionally adjust equipment that is subject to LOTO.
• Notify maintenance, etc., when equipment needs repair.
• Leave all LOTO devices in place.
• Verify equipment is safe to operate following LOTO.
• Follow all safety rules while operating the equipment.

• Any employee not using LOTO program.
• Employees tampering with the LOTO lock and Tag.
• Removing the LOTO program without Authorization.
• Must be brought to the notice of Plant Manager, EHS Manager and HR.

INTRODUCTION

What is “LOTO”?
LOTO is the acronym for LOCKOUT / TAGOUT.

OSHA (Occupational Safety & Health Administration) standard 29 CFR 1910.147 defines the system and regulations for isolating and locking various Hazardous Energy sources to prevent accidental or un-authorized startup of machinery and equipment during Servicing*, Maintenance* and Commissioning.

Lockout / Tagout involves the use of Physical Locks and restraining devices commonly known as LOTO devices to immobilize and restrain energy sources from being operated by anyone other than the person who has physically locked the energy source.

*(Service or maintenance includes erecting, installing, constructing, repairing, adjusting, inspecting, un-jamming, setting up, trouble-shooting, testing, cleaning, and dismantling machines, equipment or processes).

OBJECTIVE

Your employer has a duty to ensure you are properly equipped with the right tools and training to work safely without exposing yourself to hazards from unsecured equipment.

Each worker is required to have the knowledge and skills required for the safe application, usage and removal of the energy control devices.

ENERGY SOURCES
Electrical, Mechanical, Hydraulic & Pneumatic comprise some of the most common energy sources. Steam, Gravity, Potential, Chemical and Radiation are other energy sources existing independently or as a result of reactions between a combination of different media or energy sources.

Uncontrolled energy causing the sudden and unexpected movement of a machine or any part of a machine can kill or injure you. Each year workers are killed, body parts are crushed, and others lose fingers, hands, arms. For example, in just two years in California (2005 and 2006) there were 9 fatalities and 113 amputations.

Why do accidents happen?
Some common reasons include:

• All hazardous energy sources were not de-energized and controlled.
• Equipment was not locked out or tagged out after powering off.
• Did not actually think through the steps of the energy control before starting work.
• Inadequate or no training.
• Took shortcuts.

WARNING
It is important to remember that just turning off a switch is not the same as lockout because there is still energy in the switch. If there is a short at the switch or the machine is accidentally turned on, it will energize and cause it to run.

Remember that many types of hazardous energy sources such as springs, or air, oil, steam or water pressure can cause sudden and unexpected movement of machines and hurt or kill you. To work safety, all hazardous energy sources must be controlled so that no machine or machine part can move.

Sometimes, machines and equipment must be serviced with the power on. If so, your employer must minimize the hazards to you by providing extension tools (e.g., extended swabs, brushes, scrapers) or other methods to protect you from injury. Be sure you get trained on how to use these tools or methods and always use them properly.