How does LOTO prevent loss of life

Here’s another scenario that demonstrates how LOTO can prevent casualties: John works in a paper mill where a large machine rolls paper into large spools. The machine is powered by a 480-volt motor and requires regular maintenance to keep it running smoothly. One day, John noticed that one of the drums on the machine was vibrating abnormally, a sign that it needed to be replaced. He reported the problem to his supervisor and they agreed that the rollers needed to be replaced immediately, so they scheduled a maintenance shutdown of the machine. On the day of the maintenance outage, John and his team arrive at the machine and begin preparations for maintenance work. They follow the company’s LOTO protocol by turning off power to the machine and padlocking the main disconnect switch. They then put a “Do Not Operate” sticker on the switch to warn others that maintenance work is taking place. After the power outage, John and his team continued with maintenance work. They remove the faulty roller, install a new one, and test the operation of the machine. Once they are satisfied that the machine is working properly, they remove the padlock and tag from the main disconnect switch and turn on the power. However, as soon as they turned on the power, there was a huge explosion and John’s colleague was electrocuted. The team realized there was a wiring fault inside the machine that caused the accident. Thanks to the LOTO program, John and his team are able to work on the machines safely without the risk of electric shock. However, despite the precautions they took, a wiring error inside the machine was a hidden danger that wasn’t immediately apparent. This is why regular machine inspections and identification of all potential hazards are essential to prevent workplace accidents.