Lockout/Tagout & Machine Safety: Controlling Hazardous Energy

Every year workers lose fingers, hands and lives when a machine starts, moves or releases stored energy during servicing, and when guards are missing or bypassed. This course explains the types of hazardous energy, the OSHA lockout/tagout rule (29 CFR 1910.147) and its construction counterparts, the step-by-step lockout procedure, locks, tags and group lockout, stored energy and special situations, machine guarding basics, and the supervisor and worker habits that prevent the shortcuts behind most amputations. It is an awareness-level course and does not replace the machine-specific procedures and training your employer must provide.

What you’ll learn

• Identify the types of hazardous energy and how machines injure workers
• Explain the scope and key requirements of OSHA's lockout/tagout rule and who is authorized, affected or other
• Describe the lockout steps in order, including verification and safe restoration of energy
• Choose and use locks, tags, hasps and group lockout correctly, including at shift change
• Control stored energy and understand the exceptions and special situations
• Recognize common guard types and devices and why guards must never be bypassed
• Handle contractors, periodic inspections and retraining
• Build habits that prevent shortcuts and respond to machine injuries

Who it’s for

Machine operators, maintenance technicians, mechanics, millwrights, production and warehouse workers, construction and manufacturing crews, supervisors and safety coordinators who work on or near machines and equipment. No prior lockout/tagout training is needed.

Course outline

Module 1: Hazardous Energy and How Machines Hurt 3 lessons · quiz

The forms of energy in machines, the injuries they cause, and why servicing is the most dangerous moment.

• How machines injure workers 11 min Free preview
• Forms of hazardous energy 12 min
• Why servicing is the danger zone 11 min

Module 2: The Lockout/Tagout Rule 3 lessons · quiz

What 29 CFR 1910.147 covers, who it applies to, the three groups of employees, and the energy control program.

• What 1910.147 requires 12 min
• Authorized, affected and other employees 11 min
• Energy control procedures and the program 12 min

Module 3: The Lockout Steps, One by One 3 lessons · quiz

Preparation, shutdown, isolation, applying locks, releasing stored energy, verifying zero energy and restoring power safely.

• Prepare, shut down and isolate 12 min
• Apply locks and tags, then release stored energy 12 min
• Verify, work, and restore power safely 12 min

Module 4: Locks, Tags, Hasps and Group Lockout 3 lessons · quiz

Choosing devices, writing good tags, group lockout, shift changes and what to do with someone else's lock.

• Choosing locks and tags 11 min
• Group lockout and multiple workers 12 min
• Shift changes and lock removal 11 min

Module 5: Stored Energy, Exceptions and Special Situations 3 lessons · quiz

Hydraulics, pneumatics, gravity and springs in detail, plus the cord-and-plug and minor servicing exceptions and what they do not cover.

• Taming hydraulic, pneumatic and gravity energy 12 min
• The cord-and-plug and minor servicing exceptions 11 min
• Re-energizing, robots and unusual equipment 11 min

Module 6: Machine Guarding Basics 3 lessons · quiz

Where guards are needed, types of guards and devices, and why guards must never be removed or bypassed.

• Why guards matter and where they go 11 min
• Types of guards and safeguarding devices 12 min
• Inspecting and reporting guard problems 11 min

Module 7: Contractors, Inspections and Other Industries 3 lessons · quiz

Host and contractor duties, the annual periodic inspection, retraining, and how construction and other sectors handle hazardous energy.

• Contractors and multiple employers 11 min
• Periodic inspections and retraining 12 min
• Construction, agriculture and other sectors 12 min

Module 8: Habits, Culture and Response 3 lessons · quiz

Why people skip lockout, how to build a culture where nobody does, and what to do when a machine injury happens.

• Why shortcuts happen and how to stop them 11 min
• A lockout mindset for every task 11 min
• When a machine injury happens 11 min

What’s included

• 24 lessons you can read at your own pace, on a phone or a computer
• A short quiz after every module, with the correct answer shown for any you miss
• A final exam of 25 questions (pass at 80% or higher)
• A numbered certificate of completion with a QR code anyone can scan to verify it
• Your progress saved to your account, with access that doesn’t expire

Questions

Can an employer check my certificate? Yes. Each certificate has a number and a QR code that opens a public verification page on this site.

Can I get a refund? Yes, within 7 days of purchase if you have completed less than 25% of the course and haven’t earned its certificate. Email support@toddallynmedia.com. Details are in section 13 of the Terms of Use. Payment is handled by PayPal; we never see your card details.

What do I need? A free account and any phone, tablet or computer. Questions or problems? Email support@toddallynmedia.com.