Apa itu lockout/tagout group dan bagaimana prosedurnya?

Group Lockout/Tagout adalah LOTO procedure untuk situasi dimana multiple workers perform maintenance/service pada same equipment simultaneously.

Mengapa Group LOTO Diperlukan:

Skenario umum:

• Major overhaul - mechanic, electrician, inspector work together
• Shift change - maintenance continue ke shift berikutnya
• Complex system - multiple trade involved

Hazard tanpa Group LOTO:

• Worker A finish, remove lock, energize equipment
• Worker B masih inside - tidak tahu equipment energized
• Equipment start - Worker B injured/killed

Group LOTO Methods:

Method 1: Group Lockbox System (Most Common)

Equipment:

• Group lockbox: Secure box dengan hasp yang dapat accommodate multiple lock
• Primary lock: Lock pada energy isolation device
• Individual locks: Each worker own personal lock

Procedure:

1. Isolate energy: Authorized person (supervisor/lead mechanic) isolate ALL energy source
2. Place primary lock: Lock isolation device, place key dalam group lockbox
3. Individual lockout: Each worker place own personal lock pada group lockbox
4. Verify isolation: Test equipment cannot start
5. Work proceed
6. Individual removal: Saat worker finish, remove only own lock dari lockbox
7. Last worker out: When ALL individual lock removed, supervisor retrieve key dari lockbox, remove primary lock, restore energy

Critical Rules:

• Each worker MUST apply own lock - tidak boleh rely pada orang lain
• NEVER remove someone else lock - fatal violation
• Box cannot opened sampai ALL locks removed

Method 2: Multiple Lock Hasp

Equipment:

• Hasp dengan multiple hole - dapat accommodate many locks

Procedure:

1. Isolate energy (close valve, open switch, etc.)
2. Install hasp pada isolation point
3. Each worker apply own lock directly ke hasp
4. Verify isolation
5. Work proceed
6. Each worker remove own lock saat finish
7. Last lock removed - equipment can be energized

Limitation: Hasp physical space limited - typically max 6-8 locks

Method 3: Department Lock (Less Preferred)

• One lock represent entire department/crew
• Lead person control lock
• Each worker sign in/out di log sheet

Risk: Depend on administrative control - worker bisa forget sign out

Special Situation: Shift Change LOTO

Maintenance extend beyond single shift:

Shift Handover Procedure:

1. Overlap period: Outgoing dan incoming shift both on site
2. Physical inspection: Walk through work area together
3. Briefing:
• What work completed
• What work remaining
• Energy isolation status
• Any issue/hazard
4. LOTO transfer:
• Incoming worker apply own lock BEFORE outgoing remove
• Verify: Both locks on simultaneously (brief period)
• Outgoing then remove lock
5. Documentation: Sign shift log

Example Scenario - Excavator Engine Overhaul:

Workers Involved:

• 2 Mechanics (A, B)
• 1 Electrician (C)
• 1 Supervisor (D)

Step-by-Step:

1. Supervisor D isolate:
• Disconnect battery - place key dalam lockbox
• Drain hydraulic pressure - lock valve, key dalam lockbox
2. Install group lockbox on equipment
3. Each worker apply lock:
• Mechanic A - Red lock #1 on lockbox
• Mechanic B - Red lock #2 on lockbox
• Electrician C - Blue lock on lockbox
• Supervisor D - Yellow lock on lockbox
4. Verification test: Try start switch - nothing happen ✓
5. Work commence
6. Mechanic A finish at 2pm: Remove Red lock #1, leave site
7. Others continue work
8. Mechanic B finish at 4pm: Remove Red lock #2
9. Electrician C finish at 4:30pm: Remove Blue lock
10. Supervisor D inspect work:
• All personnel clear? ✓
• Tools removed? ✓
• Guards replaced? ✓
• Remove Yellow lock (last lock)
• Open lockbox, retrieve energy isolation keys
• Restore energy - reconnect battery, refill hydraulic
• Test run equipment

Documentation:

• LOTO log must record:
• Equipment ID
• Date, time start
• Energy sources isolated
• Each worker name, lock number, apply/remove time
• Supervisor authorization signature

Audit & Compliance:

• Supervisor periodic check - all locks accounted for
• Any discrepancy - investigate immediately
• Missing lock = missing person - search until found!

Group LOTO is life-critical system - strict compliance non-negotiable!