Group Lockout Procedures
The Problem
When multiple workers are servicing the same piece of equipment, relying on a single lockout device creates serious safety risks. Without proper group lockout procedures in place, there is a danger of accidental re-energisation, which can result in severe injuries or fatalities. Today, we’ll discuss how to implement group lockout methods—such as multi-lock hasps and lock boxes—to protect all team members and ensure compliance with WorkSafe NZ expectations.
Identify the Hazards
- Accidental Re-energisation: One worker may remove a lock thinking the job is done, while others are still working on the equipment.
- Communication Failures: Poor communication between workers may lead to premature lock removal.
- Inadequate Lockout Methods: Using a single padlock for a group task increases the risk of someone unknowingly restarting equipment.
Safety Practices and Preventative Measures
1. Use a Multi-Lock Hasp:
- Attach the hasp to the energy isolation point.
- Each team member secures their individual padlock to the hasp.
- The hasp cannot be removed—and the equipment cannot be restarted—until all locks have been removed.
- Why it works: No one can restart the machine while others are still working.
2. Use a Group Lock Box:
- The lead authorised person isolates the equipment and locks out all energy sources using designated locks.
- The keys to these locks are secured inside a lock box.
- Each worker places their personal lock on the lock box.
- The box cannot be opened until the last personal lock is removed.
- When to use it: Ideal for complex equipment with multiple isolation points or when multiple workers are involved.
3. Ensure Clear Communication:
- Communicate who is working, what the job is, and when it’s safe to remove locks.
- Confirm all team members have removed their locks before restarting equipment.
Real-Life Case or Scenario
At a New Zealand processing plant, a worker removed their lock from an isolation device, mistakenly assuming the task was complete. Another worker remained inside the equipment performing maintenance. Fortunately, a multi-lock hasp prevented the equipment from being restarted, avoiding a serious incident. This highlights the importance of effective group lockout procedures and communication.
Employee Responsibilities
- Place your personal padlock on the hasp or group lock box before starting work.
- Do not remove your lock until your part of the job is fully complete.
- Confirm with the team that all locks are still in place.
- Communicate clearly with others involved in the job.
Employer Responsibilities
- Provide lockout devices suitable for group work, including multi-lock hasps and lock boxes.
- Train workers on group isolation and lockout procedures.
- Ensure WorkSafe NZ-compliant isolation procedures are documented and enforced.
Discussion & Questions
- “Have you experienced challenges when using group lockout methods?”
- “How could we improve the way we manage shared isolation tasks on-site?”
Commitment/Action Plan
Let’s commit to applying group lockout procedures on every shared task. Starting today, take responsibility for your padlock and ensure that no equipment is restarted until all locks are removed and the job is confirmed complete.
Wrap-Up
Group lockout is about teamwork and communication. Using the correct tools—multi-lock hasps and lock boxes—keeps everyone safe and compliant. Let’s work together to make our site safer.
Standards Overview
WorkSafe NZ expects businesses to identify and control hazardous energy during maintenance and servicing. Group isolation methods must ensure all workers are protected from accidental re-energisation. Written procedures and worker training are required as part of a PCBU’s duty of care under the Health and Safety at Work Act 2015.
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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