A safety lockout system is a combination of lockout devices, identification and policies designed to keep workers safe during repairs and maintenance. You can prevent accidental access to machinery, valves and restricted areas with a safety lockout system. Information to consider when implementing a system includes the number of workers who will have access to lockout areas, the types of areas that need restricting and the best way to communicate a location lock out.

Manufacturers can easily tailor safety lockout systems to a company's specific needs by purchasing safety lockout products individually. Safety lockout product providers also frequently offer lockout kits that contain a variety of lockout components. When implementing a safety lockout system, consider the following:

1. Protect workers during machinery maintenance with padlocks and hasps.

2. Add electrical and valve lockouts to your lockout safety system.

3. Use safety lockout tags to identify your safety lockout system.

4. Keep all safety lockout components in a safety lockout station.

Action Steps
The best contacts and resources to help you get it done

Find lockout system locks and hasps

Lockout systems often use color-coded padlocks and hasps. The hasp is in a location that prevents access to a piece of machinery or hazard area. Each worker keeps an assigned lock on the hasp during lockout periods so it grants access only after every worker removes his lock.

I recommend: Purchase padlocks designed specifically for lockout situations at Lab Safety Supply. These locks contain with the words "safety lockout" and are available in a range of colors. Sentry Safety Supply offers padlocks in seven different colors. Although the standard locks have different keys, the lockout system provider also sells sets of locks keyed alike. Order aluminum hasps online at TuffRhino.com. The hasps can accommodate up to six locks.

Use electrical and valve locks in your lockout system

Electrical lockout devices prevent machinery from being started by locking out access at the circuit breaker, power switch or electrical plug. Using electrical lockout devices helps keep workers safe during machine maintenance. Valve lockout devices ensure a valve doesn't accidentally open.

I recommend: Order electrical plug lockouts at Cole-Parmer. The polypropylene lockouts are heat resistant up to 300 degrees F. Find Master Lock valve lockout devices at Lock Specialty. The space-saving design allows for a variety of installations and the lockouts fit compactly into toolboxes when not in use.

Identify your safety lockout system with tags

Safety lockout tags are your first line of defense against accidental access. Safety lockout tags typically have attention-grabbing features, such as bright colors and stripes. In addition to identifying the lockout area, workers can write on the tags the reason and date of the lockout.

I recommend: Browse the Seton Identification Products safety lockout system list of tags. Choose from standard wording or order custom tags. Supply Line Direct offers bilingual safety lockout tags in English and Spanish.

Organize your safety lockout system with a central station

Safety lockout stations are a storage device for all your lockout components. These stations provide workers with easy access to organized lockout tools. Some companies sell safety lockout stations complete with lockout devices and tags.

I recommend: Browse an inventory of safety lockout stations at Hodge Products. The company offers stations that are pre-stocked with lockout devices and tags, as well as unfilled stations. Graphic Products offers user-friendly, durable safety lockout stations for stocking a variety of lockout components and tags.

Tips & Tactics

Helpful advice for making the most of this Guide

• •  When purchasing lockout system padlocks for workers, consider keying all individual workers' keys alike. This saves the time and hassle of carrying multiple keys.