Handling Unavailable Lockout/Tagout Locks
The Problem
Occasionally, you may come across a machine that has been locked out for maintenance, but the authorised worker who applied the lock is unavailable to remove it. This can happen if the worker has left for the day or if their key is found nearby. Removing the lock yourself might seem like a quick fix, but this practice is extremely dangerous and can result in serious harm or fatalities. Today, we’ll discuss the proper procedures for managing this situation to ensure everyone’s safety and compliance with WorkSafe NZ requirements.
Identify the Hazards
Unauthorised Lock Removal:
- Re-energising equipment when someone is unaware it is in operation can result in serious injury or death.
- An authorised worker may assume the machinery is still isolated and resume work, leading to potentially fatal consequences.
Lost or Forgotten Keys:
- If keys are left behind or locks are not removed as required, it may create delays and confusion, and lead to unsafe decisions.
Safety Practices and Preventative Measures
1. Never Remove the Lock Yourself:
- Only the authorised person who applied the lock may remove it, unless a formal process is followed by a Competent Person.
- Never re-energise equipment without confirmation that it is safe to do so.
2. Notify a Supervisor or Site Manager Immediately:
- Advise your supervisor as soon as you identify a lockout situation with no authorised person available.
- Supervisors must follow company protocol to resolve the issue safely.
3. Hand Over the Key:
- If you locate the key, do not attempt to use it. Give it to your supervisor to manage under controlled procedures.
4. Locate the Authorised Worker:
- Supervisors should attempt to contact the authorised worker.
- If the worker is unavailable, the lock can only be removed by a Competent Person following a documented process and risk assessment.
5. Managing Lost or Forgotten Keys:
- Notify the supervisor if a worker loses their key or forgets to remove their lock.
- Supervisors must follow company procedures for safe removal and replacement.
6. Replace Lost Locks Immediately:
- If you lose your lock key, inform your supervisor. A replacement lock must be issued to ensure continued compliance with safety systems.
Real-Life Case or Scenario
A worker failed to remove their lock at the end of their shift. Another worker found the key and removed the lock, believing it would speed things up. Unfortunately, the original worker returned later and was seriously injured, assuming the machine was still safely isolated. This situation could have been avoided by following correct lockout/tagout procedures.
Employee Responsibilities
- Never remove a lock unless you are the authorised person who applied it.
- Notify a supervisor if a lock is in place and the authorised person cannot be contacted.
- Report lost keys immediately and have locks replaced by authorised personnel.
Employer Responsibilities
- Establish clear procedures for handling lockout/tagout where the authorised person is unavailable.
- Train all staff on LOTO protocols and reinforce the consequences of unauthorised removal.
- Equip supervisors with the tools and authority to manage safe removal in accordance with WorkSafe NZ guidance.
Discussion & Questions
- What would you do if you found a LOTO lock but couldn’t contact the authorised worker?
- Have you experienced this scenario before? How was it managed?
Encourage workers to share experiences and reinforce the importance of proper procedures.
Commitment/Action Plan
Let’s commit to never removing a lockout device unless we are the person who applied it. Starting today, ensure you are familiar with the correct procedure and speak to your supervisor if unsure.
Wrap-Up
Dealing with unavailable LOTO locks is not just a policy—it’s a critical safety procedure that protects lives. By following the correct process and adhering to WorkSafe NZ guidelines, we can prevent serious incidents. Thank you for staying vigilant and committed to safety.
Standards Overview
WorkSafe NZ’s guidance on lockout/tagout requires that:
- Only the person who applied a lock may remove it, unless managed by a Competent Person following a formal risk assessment.
- Employers must have procedures in place for lost keys and unavailable workers.
- All workers must be trained in energy isolation and verification before any maintenance is carried out.
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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