Computerized Lockout Tagout Systems improve safety, save money, and increase compliance

(Virginia Beach, VA) — "There are four compliance options for dealing with OSHA lockout/tagout requirements," according to Mark Banus speaking at the Annual Meeting of the National Safety Council. "The first option is to ignore the requirement. Second: comply using paper forms and notebooks. Third: build your own in-house computer program. Fourth: buy a Maintenance Safety Software (MSS) Program."

Mr. Banus, the Executive Vice President of Stilwell & Associates of Virginia Beach, VA, is a national authority on lockout/tagout and a developer of TagLink MSS software.

Banus agrees that ignoring the requirement is really not a viable option. Current OSHA fines average $6,000 and there is always the danger of equipment damage, lost time, and even injury or death of a worker. He says that the other three options, however, are widely used, although he favors the commercial computerized system as "by far, the most cost effective option."

"The 'paper' system, using photocopied forms, notebooks, and handwritten Lockout Tagout tags appears easy but is actually the most costly", Banus says, "especially for larger or multi-plant organizations."

"Every time a lockout/tagout procedure is initiated you must start from scratch again. The time spent, probability of error, and the difficulty of information retrieval at a later time are all high cost factors. In addition," Banus notes wryly, "there are possibly times when the employee doing the procedure is untrained, poorly trained, or who may not be the most appropriate person for the job."

Maintenance Safety Software has a number of advantages including cost savings, safety improvement and increased compliance.

Banus cites four excuses he often hears from companies not using MSS. "They say that the present system works 'OK'. They say that workers don’t want to or don’t know how to use computers. Some just don’t want to change. And others say that computerized systems are too expensive."

According to Banus, MSS offers a number of bottom line advantages:

Links to CMMS software
The seamless MSS link with CMMS allows a single process to monitor assets, schedule maintenance and create tagouts, saving time and money.

Standardization
Computerized Lockout Tagout systems ensure that the same, standard, approved process is used by everyone, every time, thereby reducing variation and allowing system-wide interoperability.

Control
Four levels of security control access by workers. TagLink MSS forces compliance by locking the system until required information is entered.

Administration
With MSS, data is entered only once for repetitive procedures ensuring accuracy and standardization. MSS procedures can be printed from approved templates. Forms and Lockout Tagout tags are printed directly from the computer, eliminating the possibility of errors from misreading handwritten entries.

Audit Trail
Since all maintenance Lockout Tagout history is archived in the MSS system, audits are short because information is accurate and easy to retrieve. In the Windows environment, "point and click" is used and the onscreen forms mimic the company's own paper forms. Networked systems allow audits outside of the direct working environment without disrupting the manufacturing flow.

Cost savings and cost avoidance
MSS cuts the time necessary to create a safe worksite by as much as 93%, resulting in significant cost savings. In addition, potential costs such as OSHA fines, damaged equipment, lost time, injury or death are completely avoided or greatly minimized.

Improved Safety
Because MSS uses a single database, out-of-date information is eliminated. Standardized procedures require all entries to be completed before work is authorized, instilling worker confidence in the system.

Increased Compliance
Computerized Lockout Tagout systems make compliance simple, easy and in the best interest of both the worker and the company.

Information in databases, standardized procedures, and entry requirements all contribute to the safety of the worker, uptime for the equipment, and increased compliance," Banus believes. "Companies are assailed by ever-increasing staff turnover, equipment that is becoming even more complex, and an intensifying need to produce more with less. Computerized lockout/tagout systems allow management to meet these needs while saving money and improving safety. That’s a win-win combination for everyone."

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