Lockout/Tagout/Tryout Safety Awareness for Affected Employees

A Guide for Scrap Yard Workers

What Does “Affected Employee” Mean?

As an affected employee in our scrap yard, you work in areas where Lockout/Tagout/Tryout (LOTO) procedures are performed, but you don’t personally service or maintain the equipment. You operate machines that may be locked out by authorized employees, or you work near equipment that’s being serviced.

Understanding your role is critical to staying safe and keeping your coworkers safe.

Why LOTO Matters in Scrap Yards

Scrap yards present unique and serious hazards. Our equipment—including balers, shears, conveyors, cranes, and sorting systems—can cause catastrophic injuries or death if unexpected startup occurs during maintenance or servicing.

The dangers you face:

Crushing injuries from balers and compactors
Amputation hazards from shears and cutting equipment
Entanglement risks from conveyors and sorting lines
Electrocution from electrical systems
Caught-between hazards from hydraulic systems and heavy machinery
Falling materials from cranes and magnets

LOTO procedures prevent these tragedies by ensuring machines stay off and de-energized during service work.

Your Responsibilities as an Affected Employee

1. NEVER Operate Locked or Tagged Equipment

If you see a lock or tag on equipment controls, DO NOT:

Remove the lock or tag
Attempt to operate the equipment
Bypass the lockout device
Ask someone else to remove it for you

This is non-negotiable. Removing a lock or tag could kill a coworker who is inside or working on that machine.

2. Recognize LOTO Devices

Know what to look for:

Red locks with employee names/photos
Danger tags stating “DO NOT OPERATE”
Lockout hasps securing multiple locks
Valve lockouts on hydraulic and pneumatic systems
Circuit breaker locks on electrical panels
Cable lockouts on equipment controls

If you see any of these devices, the equipment is OFF LIMITS until they’re removed by authorized personnel.

3. Understand “Tryout” Requirements

“Tryout” means testing that equipment won’t start before service work begins. As an affected employee, you may witness:

Authorized employees attempting to start equipment after lockout
Equipment remaining unresponsive despite pressing start buttons
Energy testing procedures

Never interfere with tryout procedures. These tests confirm the equipment is truly de-energized.

4. Respect Work Area Boundaries

When equipment is locked out:

Stay clear of the work area unless authorized to be there
Follow posted barriers, caution tape, or warning signs
Don’t reach into or around locked-out equipment
Avoid creating new hazards near the maintenance zone

Common Scrap Yard Scenarios

Scenario 1: Baler Maintenance

You arrive to work and see your hydraulic baler has locks on the control panel and electrical disconnect. A mechanic is inside clearing a jam.

Your action: Use alternative equipment or wait until the baler is returned to service. Check with your supervisor for reassignment during the downtime.

Scenario 2: Conveyor Repair

A conveyor belt you normally load has multiple locks and a “DANGER: DO NOT START” tag. The authorized employee is replacing damaged sections.

Your action: Never add material to the conveyor or remove any locks. Stage your materials safely away from the conveyor until it’s cleared for operation.

Scenario 3: Shear Blade Replacement

The guillotine shear has been de-energized, and you see locks on multiple energy sources (electrical, hydraulic, and pneumatic).

Your action: Avoid the entire shear area. Blades are heavy and dangerous, and unexpected movement could be fatal to maintenance workers.

What to Do If…

You Need to Use Locked-Out Equipment

Contact your supervisor immediately
Never rush or pressure maintenance staff
Use alternative equipment if available
Understand that safety takes priority over production

You See Someone Tampering with LOTO Devices

Stop them immediately if safe to do so
Report to supervision right away
Document what you witnessed
Remember: tampering with LOTO devices can result in termination and criminal charges

You’re Unsure if Equipment is Locked Out

Assume it’s locked out if you see any device you don’t recognize
Ask an authorized employee or supervisor
When in doubt, DON’T operate it

You Find a Lock Without a Tag (or vice versa)

Treat it as locked out
Report the missing component to your supervisor
Don’t assume it’s okay to operate

Group Lockout Situations

In scrap yards, multiple workers often service large systems simultaneously. You may see:

Many locks on a single lockbox
Different colored locks indicating different trades
Extended lockout periods for complex repairs

Your role: Stay completely clear of these areas. Group lockouts mean multiple people’s lives depend on those devices staying in place.

Communication is Critical

Before Starting Your Shift:

Check with supervision about any locked-out equipment
Note which machines are unavailable
Plan your work around maintenance activities

If You Have Questions:

Ask your supervisor or the authorized employee
Never assume or guess
It’s better to ask 10 times than to make one fatal mistake

Before Leaving Your Shift:

Report any new locks you’ve observed
Communicate equipment status to the next shift
Don’t leave others uninformed about LOTO situations

Your Rights and Protections

As an affected employee, you have the right to:

Refuse to operate locked-out equipment without retaliation
Receive LOTO awareness training upon hire and annually
Report violations without fear of punishment
Work in an environment where LOTO procedures are followed

If you feel pressured to bypass LOTO procedures, report it immediately to management or OSHA.

Remember: Locks Save Lives

Every lock represents a human being who trusts their coworkers to keep them safe. In our scrap yard, we handle powerful, dangerous equipment daily. The few minutes lost to LOTO procedures are nothing compared to the permanent loss of a life or limb.

The Bottom Line:

See a lock? Don’t touch.
See a tag? Don’t start.
Have questions? Ask.
Someone’s life depends on your awareness.

Training and Resources

All affected employees must complete LOTO awareness training that covers:

Recognition of lockout/tagout devices
Your specific responsibilities
Limitations on your actions
Consequences of violations

Stay alert. Stay informed. Stay alive.

For questions about LOTO procedures, contact your supervisor or safety manager immediately.

Lockout Tagout AFFECTED Employee Safety Training