LOTO Risk Assessment and Plan Formulation

Risk assessment and plan formulation: For the equipment to be maintained, the Equipment Department, the Safety Department, and the maintenance team jointly conduct a risk assessment to identify potential energy sources (such as electrical energy, mechanical energy, hydraulic energy, chemical energy, etc.). For instance, when it comes to the maintenance of injection molding machines, it is necessary to clearly define the three major energy sources: “power switch, hydraulic pump, and heating ring”. Based on the assessment results, formulate the “LOTO Operation Plan”, clearly defining the maintenance content, energy isolation points, locking sequence, responsible persons and operation time.
Safety material verification: Prepare dedicated LOTO locks (one unique key per person, not replicable), warning signs (marked “Under maintenance, No operation allowed”, “Name and contact information of the person in charge”), energy isolation tools (such as valve locks, power plug locks, circuit breaker locks), personal protective equipment (PPE), etc. Locks must comply with national mandatory standards, have uniform colors and unique identification. It is strictly prohibited to use ordinary padlocks as substitutes. A certain electronics factory once used inferior locks. During maintenance, the locks broke, causing the equipment to start wrongly and resulting in minor injuries to the employees.
Personnel training and briefing: All personnel involved in the maintenance shall receive specialized training on the LOTO process. Only after passing the assessment can they take up their posts. Before starting work, a pre-shift meeting should be held, where the person in charge should once again explain: clarify the responsibilities of each position (such as who is responsible for locking, who is responsible for supervision, and who is responsible for unlocking), and the emergency handling procedures (such as how to deal with lock damage), to ensure that everyone is clear about the operation risks and operation norms.