Case-study

What are the key steps to implement Lock-Out-Tag-Out to prevent personnel injury?

Safety Safety

Problem

ManufacturingCo. currently uses Lock-Out-Tag-Out (LOTO) procedures in its mills to prevent risks of personnel injuries in production. However, these procedures vary a lot across different mills. Sprintly team created a cost-efficient and scalable LOTO process workflow for ManufacturingCo. to standardize and implement LOTO processes across all EquipmentCo.’s mills.

Outcomes

9

Solution implemented at 9 mills

Situation

ManufacturingCo. used Sprintly team to deepen their understanding of key steps in the LOTO process. This project helped ManufacturingCo. to identify key personnel for the LOTO process, addressed different risks and provided a detailed LOTO process map and relevant equipment to use in LOTO.

Our approach

The key questions addressed in the project:

Q1. Who are the key personnel and what are their responsibilities for LOTO?

Q2. What are the scenarios in which LOTO is utilized?

Q3. What are the critical factors for choosing LOTO equipment features e.g. colour, number of locks, types of locks?

Methodology

Phase 1: Current LOTO policy research at ManufacturingCo.

To draft the LOTO process map for use-cases accurately, Sprintly team first conducted background research in phase 1 by reviewing the current LOTO policy, extracting the current high-level LOTO process, identifying use-case scenarios for LOTO applications and key personnel to interview.

Phase 2: LOTO process map creation using benchmark mills

Based on the background research in phase 1 and the benchmark interviews with peer companies, Sprintly team created detailed LOTO workflows for four different LOTO stages: shutdown and isolation, LOTO and test, personal padlocks, and unlocking and documentation. In each LOTO stage, Sprintly team also provided detailed solutions for relevant equipment usage and document standardization.

Phase 3: Close cooperation with client for a suitable outcome

Mill-specific procedures were analyzed with ManufacturingCo. to provide a standard LOTO solution for all mills. Sprintly team addressed different risks that can arise in the LOTO process and provided solutions to prevent these risks. Sprintly team also made recommendations for LOTO equipment that is visually easy to identify and can be used in a standardized way minimizing complexity in the process and making it cost-efficient.

Results

ManufacturingCo. piloted the new LOTO process at one of its mills and will implement it across all post the pilot.

Testimonial

This work will be used in real life and save hundreds of lives!”