The Consequences of Poor Lockout Tagout LOTO Practices

Lockout Tagout (LOTO) Failures: A recipe for disaster for Food Manufacturers

In the UK food and beverage industry, Lockout Tagout (LOTO) practices are essential for ensuring the safety of maintenance engineers and frontline workers. Several high-profile incidents have shown that neglecting LOTO protocols can lead to severe injuries and substantial financial penalties. This article explores the risks of non-compliance, real-life case studies, and how robust training programmes can help prevent such incidents.

A recent and particularly notable case in the UK involved a food manufacturer being fined over £350,000 after an employee lost a finger while conducting maintenance on machinery. The Health and Safety Executive (HSE) found that the employer had failed to adequately isolate machinery due to inadequate training on Lock Out Tag Out procedures, resulting in the unfortunate incident. This case serves as a stark reminder of the importance of LOTO compliance and the need to provide related training to concerned maintenance staff to mitigate against workplace accidents.

In another incident, Oriental Delight (UK) Limited, a food manufacturer, faced a £150,000 fine after HSE inspectors discovered repeated failures in machine guarding and LOTO practices. Despite previous warnings, the company did not implement the necessary changes, leading to serious legal repercussions under the Provision and Use of Work Equipment Regulations 1998​

Key LOTO Practices for Food Manufacturing

1. Comprehensive Risk Assessment and Isolation: Before maintenance, it is crucial to fully de-energise and isolate equipment from power sources. The HSE has emphasised that many workplace accidents involving machinery occur due to insufficient energy isolation.
2. Clear Labelling and Locking: Lockout devices and clearly labelled tags are critical in ensuring that machinery is not accidentally reactivated during maintenance. These visual warnings significantly reduce the risk of accidents.
3. Regular Employee Training: According to the HSE, inadequate training is one of the leading causes of workplace injuries involving machinery. Regular LOTO training ensures that workers remain competent in safe isolation procedures. This is particularly important in food manufacturing, where high staff turnover can lead to unforeseen knowledge or skills gaps.

The Costs of Non-Compliance to LOTO protocols

Ignoring LOTO protocols can have devastating consequences for a business:

• Hefty Fines and Legal Action: As evidenced in the cases above, businesses can face fines amounting to hundreds of thousands of pounds for failing to implement proper LOTO measures. These fines are typically followed by legal action and compensation claims.
• Reputational Damage: Public investigations by the HSE often lead to significant reputational damage, with findings shared widely and publicly across industry publications and regulatory bodies. This can potentially result in punitive measures including the loss of contracts and diminished stakeholder trust.
• Reduced Productivity: Implementing proper LOTO procedures can improve operational efficiency. A 2020 study found that businesses adopting robust LOTO practices saw a 25% reduction in maintenance-related downtime, allowing machinery to be recommissioned more quickly​.

Industry Expert Insights

Phil Chambers, Managing Director of Strategic Safety Systems, highlights, “Many businesses underestimate the long-term damage caused by failing to adopt proper LOTO measures. It’s not just about avoiding fines—effective LOTO systems prevent life-changing injuries, improve morale, and reduce operational risks.” (Source: IOSH Magazine).

Similarly, Richard Jones, Head of Policy and Regulatory Engagement at the Institution of Occupational Safety and Health (IOSH), has stated, “LOTO compliance should be non-negotiable for any business operating high-risk machinery. The risks of non-compliance are far too great—both in terms of human life and financial impact” (IOSH, 2021).

Take Action: Enhancing Your LOTO Practices

LOTO should be a core component of any food manufacturer's safety protocols. A systematic approach to energy isolation, combined with regular employee training, not only prevents accidents but also enhances productivity. For companies in the food manufacturing sector, where the pace of production is critical, investing in safety measures can also help avoid costly disruptions and downtime.

At Nvolve, we help businesses in the food and beverage industries integrate robust and easily deployed training procedures that ensure compliance with LOTO regulations, retailer audits and broader health and safety standards.