Project Specifics

The Occupational Safety and Health Administration (OSHA) cited the manufacturing facility for failing to conduct required lockout/tagout (LOTO) procedure annual inspections.

LOTO procedures facilitate the proper shut off of equipment for maintenance or repair work. The OSHA citation gave the facility a time frame of approximately two months to complete the 1,000+ overdue LOTO procedures inspections. The client determined they would need an outside consultant along with in-house resources to complete the overdue inspections within this time frame.

Geosyntec Scope of Services

Geosyntec completed the overdue inspections during on-site visits over the course of three weeks. Geosyntec used a two-part strategic approach to ensure there was proper inspection documentation and prepare the facility to be able to complete these LOTO in-house in the future.

Mobile Relational Database Forms

Geosyntec developed a mobile relational database form for the completion of inspection documentation in the plant at the LOTO equipment site. Using this type of form was crucial for tracking completed LOTO procedures and the required inspection information. Other methods that would require an internet connection to electronically track periodic inspection requirements were not feasible due to unreliable Wi-Fi connection and cell phone coverage in the plant. Using the mobile relational database form, Geosyntec was able to track the inspections and develop a reference spreadsheet for the client.

Training of Additional LOTO Inspectors

The client had three trained inspectors at the start of the project, all of whom had other job responsibilities and could not devote the time required for completing the LOTO inspections. Geosyntec trained 13 in-house employees to complete the periodic inspections in preparation for future compliance.

Each inspection involved observing an authorized employee complete a LOTO procedure, verifying the equipment’s energy was sufficiently controlled by the employee, and ensuring procedural steps were properly documented. While completing the inspections, Geosyntec found several LOTO procedures with incorrect or outdated information and identified equipment that did not yet have a procedure developed. Geosyntec assisted in revising and updating approximately 300 errant LOTO procedures to reflect current practices and conditions.

Notable Accomplishments

Geosyntec was able to complete more than 1,000 OSHA mandated LOTO inspections in the over 225,000 square foot manufacturing facility in a one-month period. Geosyntec trained a number of our client’s staff to facilitate future in-house inspections.

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