Manufacturing
Manufacturing Lockout Program Rebuild
A multi-shift fabrication plant replaced generic LOTO paperwork with equipment-specific procedures supervisors could enforce during maintenance windows.
Challenge
The facility had a written lockout program, but equipment-specific procedures were incomplete, temporary workers were unsure of expectations, and audits repeatedly found inconsistencies between shifts.
Approach
- Facility walkthrough focused on high-energy equipment and maintenance interfaces
- Prioritized procedure development for the highest-risk machines
- Supervisor coaching on verification and group lockout practices
- Training refresh for authorized and affected employees
Outcomes
- Equipment-specific procedures completed for priority assets
- Clear ownership assigned for periodic inspections
- Improved consistency across day and night maintenance crews
- Audit findings reduced to documentation follow-ups instead of field gaps
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