An essential part of any skills training is demonstration. This is especially true when it comes to lockout training as different machines have different locking mechanisms. Show employees the tags your operation uses and demonstrate how to place them on the controls when they are locked down and need to remain off. The lockout shuts the machine down so it can be worked on, while the tags notify others that the machine should not be turned back on. Show employees where to find the tags; how to lock out the machine; how to attach the tag; and how to remove it.
On-site and off-site seminars are available for training employees to OSHA standards. If your operation is part of a larger company, the corporate office may have developed standard seminars that the manager or human resources department will deliver at regular intervals or during orientations. There are also many safety and manufacturing consultants who will deliver seminars to your employees.
Job breakdown is the backbone of any skills training. The job breakdown lists the task to be performed; steps involved in doing it; and the standards for successfully completing the task. The job breakdown is developed with the input of those who perform the job on a regular basis. This breakdown can be posted where employees can see it; be included in their employee handbook; or used to develop training and coaching sessions. There should be a separate job breakdown for the task of locking out machines. Some operations may need multiple job breakdowns if lockout procedures are different for different machines.
Some operations will hire a consultant to come in and audit their lockout program. The results of the audit act as a training assessment to identify areas where additional training is needed. The audit can also be given directly to employees as a training tool for helping them identify where they need to improve their skills.
Employees working with machines typically prefer hands-on training such as demonstrations and simulations. However, lockout training is often given to others in the company who prefer Internet-based training. Support and managerial staff may benefit from some of the software that has been developed to teach lockout procedures and explain their importance. OSHA offers a downloadable training seminar on lockout/tagout procedures that includes a tutorial, discussion of major issues and interactive case studies.