Master keys and duplicate keys in the facility—where the presence of those keys is intentional—need to be carefully managed. Processes for managing and accessing keys should be explicitly stated in the company’s lockout program. If a lock is abandoned and the facility wishes to reenergize the equipment, duplicate keys are an alternative to a bolt cutter, but it is imperative to have a rigorous process for accessing those keys.
It is possible for the unintentional presence of duplicate keys as well. The larger the key system, the more critical it is to work with the lock manufacturer to chart the keys. Key charting tracks which key codes are shipped to a specific facility and, for standard orders, ensures that new locks have the same key codes as existing locks. If you are replacing a lock in a set or expanding the number of locks in a set, you may request locks be built using an existing key code.
Exploring Lock Functionality
Padlocks function either as key-retaining or non-key-retaining. Choosing one or the other depends on how the locks are used. Making the right selection can mitigate frustration and improve productivity.
Key-retaining locks: These have a shackle that cannot be in the open position without the key being in the lock and turned to the unlocked position. This is a benefit if locks are being used for personal lockout and the number of locks installed is relatively moderate. If authorized employees do not have the key to the lock in their pocket, they should investigate and make sure the lockout is secure before commencing with any work.
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Non-key-retaining locks: These locks do not require the key to be inserted and turned to have the shackle open. These locks might be preferred in group lockout, where job locks are applied in large quantities and having to manually open and close the lock at each isolation point is cumbersome and adds time to the installation process. To maximize productivity of group lockout, keep the shackles open after removing them when the job is complete and store them in a location with minimal exposure to dust and debris. The process for installing locks for the next job will be significantly more streamlined.
Finding Other Efficiencies
A final opportunity to optimize productivity is deploying personal locks to support routine machine servicing and changeovers. If an employee must cover a lot of physical area and there is a nominal number of locks—such as two or three—typically required for lockout, it makes sense to assign locks to the individual.
Also, if a machine has to be locked out frequently—as in the case of frequent changeovers—or requires a relatively high number of locks and devices, consider placing the lockout equipment at the machine, where it’s easily accessible for the next maintenance or changeover event.
Requiring an employee to cross a facility to get lockout equipment is never a good idea. This is especially important for quick-turn maintenance. It shouldn’t take four minutes to access lockout equipment to complete a 15-minute servicing job. The extra movement is unproductive and wasteful, and the temptation to skip the long trip to get the lockout equipment doesn’t align well with compliance and accountability.
A successful lockout program keeps a company compliant and productive, helps ensure employees return home in the same condition they arrived and enables safety managers to sleep well at night knowing their time, effort and commitment helped to make all of that happen.
How does your company optimize its lockout program? Let us know in the comments below.
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I was watching your LOTO video and at the 4:11 mark, its shows locks attached to a hasp allowing for multiple people locking out the same thing, I noticed that the green lock show an major error. It shows that one of the locks is not locked to the hasp but is instead locked to another lock. Decent video except for that particular issue.
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