The few minutes before the dismantling determined life and death.
In 2019, a car parts factory in Ohio, USA, witnessed a preventable tragedy that could have been avoided. The maintenance team completed the maintenance work on the press machine. Before removing the LOTO lock to restore the energy, the maintenance worker “glanced” at the work area and thought everything was ready. However, a torque wrench was left inside the press machine mold – at the moment of energy restoration, the press machine closed with a force of 300 tons, and the wrench was ejected and pierced through the workshop wall, nearly hitting the driver of a passing forklift.
The conclusion of the post-incident investigation was shocking: The pre-removal inspection took less than 30 seconds, yet the official checklist was never retrieved.
Removing the LOTO (Lockout/Tagout) devices is the “last mile” of the entire energy control procedure and is also a high-risk area prone to accidents. At this point, the equipment is about to resume operation, and any omissions could potentially lead to fatal accidents. This article will systematically analyze: What exactly should be checked before removing the LOTO equipment? What are the regulations, standards, and practical operations required?
The “Recovery of Operation” section of China’s GB/T 33579-2017 “Mechanical Safety – Methods for Hazard Energy Control – Lockout/Tagout” also requires:
“The work area should be inspected to ensure that all unnecessary items have been removed, the machine is in good condition, and all personnel are in safe positions. Before restoring the machine’s power, those who may be affected by the resumption of use should be informed.”
The standard also provided key details in the notes:
Before the machine is put into operation, it is necessary to visually inspect the working area to ensure that all personnel have left, all unnecessary items have been removed, and all components are functioning properly.
Check dimension one: Work area inspection – “Leave nothing behind”
2.1 Why should we clean up the work area item by item?
Any items left in the work area may become projectiles, blockages or ignition sources after the equipment resumes operation.
Check dimension two: Equipment condition check – “As good as new”
3.1 What does “operational integrity” as required by OSHA mean?
The meaning of “operationally intact” in OSHA 1910.147(e)(1) is: All components and systems of the equipment have been restored to a state where it can operate safely. This means that all the parts that were disassembled, adjusted, or bypassed during the maintenance process must be fully restored.
Check dimension three: Personnel positioning check – “No one left behind”
4.1 Clear requirements of OSHA
OSHA 1910.147(e)(2)(i) stipulates:
The working area should be inspected to ensure that all employees have been safely positioned or have evacuated.
“Safe positioning” means that every employee is positioned in a location where they will not be harmed after the equipment resumes operation. This is not “just having everyone leave the workshop” – it is about ensuring that no one is in the blind spots, movement paths or energy release paths of the equipment.
Post time: Aug-01-2026
