Experience in Implementing the LOTO Standard

Context: Why hazardous energy control requires a systematic approach

Hazardous energy control is a critical element of industrial safety. Statistics show that incidents related to the unauthorized startup of equipment or energy release often lead to the most severe injuries. In his presentation, Dmitry Zubov, Health, Safety and Wellbeing Director at Danone Group, analyzes the practical experience of implementing the Lockout/Tagout (LOTO) standard, which allowed production sites to reduce the number of such incidents to zero.

Abandoning "Turnkey LOTO" and developing an in-house standard

The speaker notes that the company's initial attempt to delegate the system implementation to an external contractor proved ineffective. Risk assessment was conducted formally, without the involvement of line personnel who knew the specifics of the equipment. This led to the creation of beautiful but irrelevant instructions that did not protect workers in practice.

As a result, the decision was made to build the system from scratch. The company developed its own standards, permit forms, and audit methodology. The key success factor was involving the employees themselves in the risk assessment process, which ensured the real applicability of procedures on-site and a deep understanding of how the system works.

Role matrix and multi-level training

Instead of hiring separate safety specialists, the company integrated LOTO functions into the duties of existing personnel by assigning specific roles:

• LOTO Managers: the most experienced experts at the plant who organize the work, conduct risk assessments, and validate standard operating procedures (SOPs).
• LOTO Specialists: trained employees (engineers, operators) who directly perform the lockout of specific types of hazardous energy.
• Auditors: employees from various departments (from logistics to plant directors) who evaluate the effectiveness of the standard and provide recommendations for its development.

Specific training sessions were developed for each group, and practical training grounds were created at the plants where personnel can safely practice energy isolation skills.

Reducing bureaucracy and technical modernization of equipment

For a safety system to work, it must be convenient and not block business processes. Using routine operations as an example, Dmitry shows how to avoid excessive paperwork. Instead of issuing dozens of permits daily for the regular cleaning of pipeline filters, the company invested in equipment modernization by installing local shut-off valves.

During the project, about 70% of the lockout points at the enterprises were technically upgraded. This allowed many processes to be transferred to the category of standardized routine procedures, integrating safety into daily work and significantly reducing time spent on bureaucracy.

Culture transformation: From cardinal rules to a bonus system

Implementing technical means and writing instructions is only part of the task. The main challenge was changing the personnel's attitude towards lockout procedures. To achieve this, the company applied a comprehensive approach:

• Zero tolerance: violation of LOTO procedures was included in the list of cardinal rules, non-compliance with which leads to dismissal.
• Positive motivation: leading indicators (number of risk assessments conducted, SOP creation, audit results) became part of the bonus program for all levels of employees.
• Explanatory work: regular demonstration of real cases and the consequences of ignoring the standard to form a conscious attitude towards one's own safety.

What you will learn from this webinar:

• Why is implementing a LOTO system solely by external contractors often doomed to fail?
• How to properly distribute roles in the energy lockout system without inflating the enterprise's staff?
• How to reduce the time spent on issuing work permits when performing routine production operations?
• What technical equipment changes are necessary for the effective and convenient application of the standard?
• How to overcome personnel resistance and make energy lockout a natural part of the workflow?