The Most Common OSHA Lockout/Tagout Violations in Printing and Publishing

In the printing and publishing industry, adherence to OSHA's 1910.147 standard is crucial for the safety of employees working around complex machinery. From high-speed printing presses to binding equipment, the risk of accidents due to hazardous energy sources is ever-present. Here, we delve into the most common lockout/tagout (LOTO) violations encountered in this sector, providing insights and strategies to prevent them.

Inadequate LOTO Procedures

One of the most prevalent issues in the printing and publishing industry is the lack of comprehensive LOTO procedures. Many facilities operate with outdated or generic procedures that fail to address the specific machinery and energy sources present in their operations. This oversight can lead to serious accidents when employees attempt to service or maintain equipment without proper guidance.

Failure to Train Employees

Another frequent violation is the failure to adequately train employees on LOTO procedures. In my experience, even when procedures exist, they're often not communicated effectively to the workforce. Employees need regular, hands-on training to understand the risks associated with hazardous energy and how to correctly apply LOTO measures. Without this, the likelihood of accidents increases significantly.

Improper Use of LOTO Devices

Improper use of LOTO devices is another common issue. I've seen cases where workers use inadequate or damaged devices, or they fail to apply them to all energy sources connected to a piece of equipment. This can result in unexpected machine startup or the release of stored energy, leading to injuries. Ensuring that all employees understand the correct application of LOTO devices is essential for safety.

Lack of Periodic Inspections

OSHA requires that LOTO procedures be inspected at least annually to ensure they are effective and up-to-date. However, many printing and publishing companies neglect this requirement. Regular inspections help identify deficiencies in procedures or training and allow for timely corrections. Without them, companies risk non-compliance and, more importantly, the safety of their workers.

Non-Compliance with LOTO During Shift Changes

Shift changes can be a particularly vulnerable time for LOTO violations. If procedures are not clearly communicated and followed during these transitions, the incoming shift may not be aware of the LOTO status of equipment. This can lead to unauthorized removal of LOTO devices or attempts to restart machinery without proper clearance, posing significant risks.

To address these common violations, printing and publishing companies should consider implementing a robust LOTO program. This includes developing machine-specific procedures, conducting regular training sessions, ensuring the use of proper LOTO devices, performing periodic inspections, and maintaining clear communication during shift changes. By taking these steps, companies can significantly reduce the risk of accidents and ensure compliance with OSHA's 1910.147 standard.

Based on available research, individual results may vary, but the implementation of a comprehensive LOTO program can lead to safer workplaces and fewer violations. For further guidance, companies can refer to OSHA's resources or consult with safety experts to tailor their LOTO procedures to their specific needs.