GUIDE TO INTRODUCING A LOTO SYSTEM ACCORDING TO MSL 1.1 - 3 steps to a secure - MSL 1.1 STANDARD - MAX Systems GmbH
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MSL 1.1 STANDARD
Lockout Tagout
2019 / 2020
GUIDE TO INTRODUCING A LOTO
SYSTEM ACCORDING TO MSL 1.1
Just
3 steps e
ur
to a sec
LOTO
system!
www.maxsystems.eu
MSL 1.1 Standard: Lockout Tagout Guide to the Introduction of a LOTO System According to MSL 1.1
»Guide to the Introduction of a LOTO System According to MSL 1.1
Over 90% of all accidents are caused by human error. There are always situations that
cannot be premeditated or excluded, so that protection from accidents due to human error What is LOTO?
are not 100% possible. However, there are safeguards that can reduce the number of these LOTO is the abbreviation of Lockout Tagout, in En-
errors, especially in the area of occupational safety. LOTO can help here. glish „lock and tag“. Lockout Tagout stands for the
secure locking and Taging of energy sources during
Are you interested in LOTO and would like to familiarize yourself the maintenance and repair of machines and equip-
with the LOTO System? ment. It was developed in the US, where the number
Or do you already have a security system and want to improve it? of accidents at work has already been reduced by
over 70% thanks to LOTO. Lockout Tagout is beco-
In order for the LOTO system you introduce to be understood and followed by your co- ming increasingly popular in Europe too.
workers, you should follow the following guiding principle:
Keep it simple!
In the following guide, we will show you a way to introduce a simple LOTO system in just
three steps. Many lock manufacturers and dealers make this subject very complicated and What is the MSL 1.1 Standard?
complex in order to earn money with uncertainty and fear. That is unnecessary! The MSL 1.1 standard was developed by MAX Sys-
The simpler a LOTO system is, the safer it is, because it is understood by everyone and can tems to simplify the introduction of a secure lockout
be easily applied while working on machinery and energy sources. If all workers can trust tagout system. According to our standard, the start
the system, it is a secure system. in a LOTO system can already be made with three
locks. The use of different closing locks avoids acci-
A LOTO system must be run in the respective national language with all its components. dents resolving from the incorrect removal of locks,
We at MAX Systems will be glad to help you with the implementation and will be happy to since it is not possible to switch on the system until
assist you in all your needs! MAX Systems is a distributor for LOTO products from different every employee has removed their lock.
manufacturers and is a manufacturer of customized labelling solutions. MAX Systems has The clear labelling of systems and energy points
created the MSL 1.1 standard for German as well as other country specific requirements, according to MSL 1.1 is the cornerstone of a suc-
to make work safer. cessful and secure LOTO concept. It ensures under-
standing and avoids errors during use. A successful
implementation of the concept requires training of all
concerned employees. Due to the simple system, this
can be done in a maximum of 30 minutes.
»3 steps to a secure LOTO system:
Step 1: Step 2: Step 3:
Naming and labelling of Provide Instructing
machines, equipment and areas Interlocks Employees
2 Just call us: +49 (0) 47 63 / 9 45 950
Introduction of a LOTO System According to MSL 1.1 MSL 1.1 Standard: Lockout Tagout
»Introduction of a LOTO System According to MSL 1.1
Step 1:
Naming and labelling of machines, equipment and areas
• Attach identification label to the machine
• Attach notes (notes on the applicable shut-down procedure, for the main responsible employee,
on the energy points (number, type and location) and on possible non- unlockable energies)
TIP: Systems
se MAX
If you u u will
bels, yo
• Mark energy points
• Clearly identify non-releasable energies LOTO la ualify fo
r
tically q
automa r d !
• Create shutdown procedure (lockout) Standa
MSL 1.1
A clear identification of the machines, systems and work areas enables a clear identification and e 10.
See pa g
creates clarity for all employees.
When creating a unique label, the LOTO labels from MAX Systems will help you.
The design of the labels catches the eye and ensures uniform labelling. LOTO labels in various sizes can be found on page 7.
LOTO Identification label LOTO Energy Point Label LOTO Energy Point Label LOTO Foil Tape Marking
for Non-Releasable Energies for Non-Releasable Energies
Development of shutdown procedure: What are shutdown procedures?
Create your shutdown procedures based on the created identification labels and energy A shutdown procedure is a description of the steps
point labels. The development of shutdown procedures requires knowledge of the ma- required to safely shut down a particular machine
chines and equipment. Because of this, we advise you to do this work step by step together and installation for service and maintenance. The
with the relevant staff. processes, together with information about the re-
Subsequently, the checklists for the shutdown procedures should be made available to sponsible person and the required equipment, are
every employee. This can be done analogously (e.g. as a notice, sign or folder) or digitally summarized in a checklist.
(e.g. PDF or software such as SignMax ID (see page 10).
The gradual establishment of a shutdown procedure (checklist) avoids errors. Example: TIP: utdown
our sh
• Preparation, prepare tools and materials Create y the Si-
e d u r es with
• Inform staff (Reason? How long? Goal?)
p r o c asy and
a x ID - ver y e
• Shut down in the prescribed order
gn M nd!
understa
• Observe special cases in case of emergency shutdown etc. clear to ation
re inform
• Drain, discharge, block, secure or dissolve stored energies and kinetic energies Find mo 10.
• Isolation of energy points with locking systems. Lock and Flag Arrow-Circle-Right Lockout Tagout on pa ge
• Check freedom of energy!
Step 2:
Provide interlocks
• Provide shut-off devices for the identified energy points
• Provide interlocking locks in the appropriate colours
• Provide hangtags (see page 6)
According to your machinery and equipment, you should have sufficient shut-off devices in stock and locks with a locking system that suits your operation.
For this we recommend padlocks in different colours according to MSL 1.1.
For many areas there are universally applicable locks. This saves you money and makes every lock efficient. Our staff would gladly take the time to display
the various locks on site with samples.
Just contact us! Tel.: +49 (0) 47 63 / 9 45 950 oder info@maxsystems.de.
Step 3: TIP:mployees
Instructing staff your e
Integrate of the
After the MSL 1.1 standard, you create an easy to understand and effective lockout tagout system. The e in tr oduction
with th xpand it
training of the employees takes a maximum of 30 minutes. Afterwards each employee understands the O s y s te m and e
LOT step.
function of the LOTO system and can use it reasonably. step by r
togethe
To grow tu r e.
cure fu
Further • Scope: The LOTO system should apply to all internal and external staff. for a se
• The Industrial Safety Ordinance may need to be adjusted and changed.
notes: • If necessary, adapt the regulations for work on the corresponding energies.
www.maxsystems.eu 3
MSL 1.1 Standard: Lockout Tagout Classification of locks according to MSL 1.1
» Classification of locks according to MSL 1.1
Grün Signal Lock:
It is the first lock placed on the group lock and it is the last lock that is taken to release
the keys for the power points (machine locks). Every machine, facility, area or process
has a green lock and a group lock!
Rot Machine Lock:
The machine locks are group locks, which must be available starting with a number of
two, to be locked energy points.
Blue, Yellow & Orange Staff Lock:
The locks for the employees are personalized and have only one key (different closing).
There is no MasterKey for these locks. Locks marked with the name of each employee
provide a direct overview of which employee is currently working on the machine or
system. For this, engravings on the locks or individual labels, possibly with a QR code
(see SignMax PL on page 10) can be used as a more flexible variant.
Turquoise, Violet & White More colours for employees
or group assignments:
Depending on the employee structure or worker columns, these colours can be used.
These are also personalized locks.
Black Manager Lock:
Can be used if it is only allowed to be switched on again after certain consideration and
consultation with the management or for work that extends over several shifts or days.
Example of use:
WAY:
BY THu Ewill receive all
A lock for electrical connections with a locking
bracket and three employee padlocks (here: yel-
low by an electrician, blue by a locksmith and a
yo
green signal lock) With us standard
O p ro d ucts as
LOT .
an labels
with Germ
est in
On requ
gua ges.
other lan
4 Just call us: +49 (0) 47 63 / 9 45 950
Examples of locking systems according to MSL 1.1 MSL 1.1 Standard: Lockout Tagout
» Examples of locking systems according to MSL 1.1
Example 1: Example of use:
Machine with 1 energy point: electrical energy 1 420 multiple striker with
S32 padlocks
2 employees: 2 electricians
Process:
The machine is switched off by the department manager
and secured against being switched back on with a lo-
cking bracket (see figure on the right) and a green lock.
As the two electricians start their work, they each bring
their yellow lock to the interlocking bracket for intrinsic
2
safety. Once the work is done, it will be reported to the su-
pervisor and both electricians will remove their yellow lock
from the interlocking bar. The supervisor then removes his
green lock and the machine can be turned on again. A red
machine lock is not necessary here, as there is only one
energy point.
Example 2:
Machine with 3 energy points: electrical energy, compressed air and process water.
5 employees: 2 locksmiths, 2 electricians and 1 contractor employee:
Locking of the 3 energy points Locking the
on the machine Group Locking Box
1 2 3
Process:
The head of department removes the red machine locks for the 3 energy points from the
Group Locking Box, as well as the green signal lock. With the red locks he locks the energy
points of the machine. He then puts the three keys of the red locks in the group lock box
and locks them with the green key lock.
The five employees can now safely start their work. Everyone puts their personal lock into
the group lock box. After the work is completed and staff have gradually removed their
personal locks from the group lock box, the head of department can remove the green lock
and release the power points with the keys of the red locks he removes from the group lock
box. Then the machine is restarted.
Example of use:
S600 group lock box
with S32 padlocks
www.maxsystems.eu 5
MSL 1.1 Standard: Lockout Tagout Examples of locking systems according to MSL 1.1, Hang Tags
»Examples of locking systems according to MSL 1.1
Example 3:
Plant with 4 machines in 3 buildings integrated in one process. Each machine has 5 energy points.
8 locksmiths, 4 electricians and 6 contractors worked on the overhaul of the system for 4 days..
Locking the Locking the Keys of the Locking the
Locking of the 5 energy Locking of the 5 energy group box 1 group box 2 group box 1-4 group box 5
points to machine 1 points to machine 2
3
The employee locks are attached
to the group lock box of the machine
Locking the Locking the
they are working on.
group box 3 group box 4
Locking of the 5 energy Locking of the 5 energy
points to machine 3 points to machine 4
8x 6x
1 2 4 5x
4x
Process:
The manager or the authorized person switch off all 4 machines. The energy points are secured against reconnection with
the red locks and the keys are inserted into the corresponding Group Locking Box. The authorized person places the green
locks on the Group Locking Box for the respective system. For each machine there is now a Group Locking Box.
The keys of the 4 green locks are now placed in a fifth group lock box and secured again with a green lock. All internal and
external employees hang their personalized lock on the respective group lock box of the machine they are working on. The
works manager hangs a black lock on each group lock box while working, thus preventing general restarting. When all the
work has been completed, the employees have removed their locks and the works manager has taken over the work, the
system can be restarted completely to specification.
The locking system:
It is clear in all examples that you can start with only three locks
in a LOTO system and this system is extensible to infinity.
A system purchased from MAX Systems is always expandable!
»LOTO - Labelling • Can be used indoors or outdoors Do not switch!
Men at work
Hang Tags for your locks • Material: plastic 0.5 mm Name:
Contact:
MAX SYSTEMS
MSL 1.1
Item No.: 4
Do not
Es wird gearbeitet!
Do not operate Name:
operate Contact:
MAX SYSTEMS
MSL 1.1
Item No.: 5
Do not Do not switch! Men
Men at work
operate at work
Do not operate
Name: Name: Name:
Name:
Contact: Contact: Contact:
MAX SYSTEMS MAX SYSTEMS MAX SYSTEMS
Contact:
MSL 1.1 MSL 1.1 MSL 1.1 MAX SYSTEMS
MSL 1.1
Item No.: 1 Item No.: 2 Item No.: 3 Item No.: 6
LOTO Hang Tags
Item No. Description Size Unit Price/PU
See Fig. Portrait format with print 80 x 147 mm 10 Pcs. € 13.00
See Fig. Landscape format with print 160 x 55 mm 10 Pcs. € 12.00
6 Just call us: +49 (0) 47 63 / 9 45 950
LOTO - Labelling MSL 1.1 Standard: Lockout Tagout
»LOTO – Labelling with the LabelMax series from MAX Systems
Film cartridge with LOTO labels
Prefabricated LOTO labels that can be individually printed with our LabelMax Labelling Systems. Made of self-adhesive film for indoor and outdoor use. UV
resistant, scratch-resistant, seawater-resistant and resistant to many solvents (eg. turpentine / petrol), various alkalis and acids.
The LOTO Identification Label should contain the following LOTO Identification Label
information:
• Reference to the applicable shutdown procedure
Shape Size Pcs/Roll Item No. Price/Roll
• Note to the main responsible employee 100 x 150 mm 175 110508 € 175.00
• Note on energy points (number, type and location)
50 x 75 mm 450 110509 € 159.00
• Reference on possibly non unlockable energies
Example of use:
LOTO Identification Label and
LOTO Energy Point Label
Energy Point Label
Shape Size Pcs/Roll Item No. Price/Roll
100 x 100 mm 250 110510 € 174.00
50 x 50 mm 450 110511 € 138.00
LOTO Energy Point Label for Non-Releasable Energies
LOTO energy point labels identify the energy points on a Shape Size Pcs/Roll Item No. Price/Roll
machine. The rectangular label indicates energies that 100 mm 250 110512 € 173.00
can be switched off, while the round labels indicates non-
50 mm 300 110513 € 103.00
releasable energies.
Example of use:
Lock and key labels
LOTO Foil Tape Marking for Non-Releasable Energies
Form
Description Colour Size Item No. Price/Pc
Film Cartridge white 30 mm x 30 m 106743 € 65.00
Ribbon LabelMax SP3 signal red 110 mm x 125 m 110569 € 59.00
Ribbon LabelMax VX1/VS1 signal red 110 mm x 125 m 110570 € 59.00
Lock Labels
Shape Size Pcs/Roll Item No. Price/Roll
Identify your locks individually using the lock labels. With
30 x 25 mm* 750 109941 € 81.00
the lock labels, your locks are flexible, whether for the
name and telephone number of an employee or equipment *More sizes on request.
number.
With the key labels, you iden- Key Labels
tify your keys easily and
quickly. Shape Colour Size** Pcs/Roll Item No. Price/Roll
P10 white 35 x 10 mm 1000 101514 € 99.00
P13 yellow 35 x 10 mm 1000 110734 € 99.00
P21 black 35 x 10 mm 1000 110735 € 99.00
P24 safety green 35 x 10 mm 1000 110736 € 99.00
P30 orange 35 x 10 mm 1000 110737 € 99.00
P32 safety red 35 x 10 mm 1000 110738 € 99.00
P34 silver 35 x 10 mm 1000 110739 € 99.00
P38 violet 35 x 10 mm 1000 110740 € 99.00
P43 traffic grey 35 x 10 mm 1000 110741 € 99.00
P44 safety blue 35 x 10 mm 1000 110742 € 99.00
P20 brown 35 x 10 mm 1000 110743 € 99.00
**two parts
www.maxsystems.eu 7
MSL 1.1 Standard: Lockout Tagout OFFER: Starter Kit LOTO
»OFFER 1
STARTER KIT FOR LOTO Lockout!
Get started right away with the LOTO Starter Kit.
The Starter Kit includes:
Article Colour Locking System Amount Price Total Price
S601 Group Locking Box red - 1 € 127.00 € 127.00
S32 Zenex Padlock red Diverse Locking 4 € 17.00 € 68.00
S32 Zenex Padlock green Diverse Locking 1 € 17.00 € 17.00
S32 Zenex Padlock blue Diverse Locking 3 € 17.00 € 51.00
S32 Zenex Padlock yellow Diverse Locking 2 € 17.00 € 34.00
S32 Zenex Padlock orange Diverse Locking 2 € 17.00 € 34.00
Article Size Design Amount Total Price
Lock labels - number range 001-012 24 € 18.00
LOTO-Identification Label 100x150mm number range 100-150 50 € 50.00
LOTO Energy Point Label 100x100mm number range 300-450 150 € 100.00
LOTO Hang Tags 80 x 147 mm portrait format „Do not operate“ 10 € 13.00
TOTAL VALUE: € 512.00
OUR OFFER: € 189.00
Including 12 LOTO Keychains and a PDF template for the shutdown procedure.
Of course, if you need or would like other locks, we can make an equally attractive offer for you. Please feel free to contact us!
The offer also includes a free sampling with locking elements. We will send you all available interlocks for 4 weeks for illustration and testing. Our staff
will gladly assist you in choosing the right latches.
Call us! We are at your disposal. A needs assessment, which may be time consuming, is free for you in cooperation with our employees. Our experts will
gladly take the time for you! You will also directly receive a detailed overview of costs.
S32 Zenex Padlock:
• For electrical applications
• Non-conductive, dielectric bracket is non-sparking and non-magnetic
ystem
(protects against electric shock / discharges, as well as current flow This s e
between the bracket and key) can b
ed
• Suitable for use in potentially explosive atmospheres extend e!
tim
at an y
S601 Group Locking Box:
• Storage space for up to 30 padlocks
• Maximum corrosion resistance due to stainless steel construction
• All keys visible through clear, impact-resistant window
• 18 numbered locking holes for easy identification
• Stackable design simplifies storage and simplifies transportation of
multiple Group Locking Boxes
ot
Do n te
ra
ope
S
e:
TEM
SYS L 1.1
Nam
MAX MS
tact:
Con
8 Just call us: +49 (0) 47 63 / 9 45 950
OFFER: Labelling set LabelMax MSL 1.1 Standard: Lockout Tagout
»OFFER 2
LABELLING SET Tagout!
By purchasing a LabelMax Labelling System from MAX Systems and a LOTO Starter Kit (or more) you will receive the following products for free!
Article Form / Design Size Quantity / Foil cartridge Amount Total Price
Film cartridge with LOTO Identification Label - 100 x 150 mm 175 Pieces 1 € 175.00
Foil cartridge with LOTO E-Point-Label - 100 x 100 mm 250 Pieces 1 € 147.00
Foil cartridge with Lock Labels, white - 30 x 25 mm 750 Pieces 1 € 72.00
Foil cartridge with Key Labels, white - 35 x 10 mm 1000 Pieces 1 € 99.00
(two parts)
Ribbon for LabelMax, black - 150 meters - 1 € 79.00
TOTAL VALUE: € 572.00
OUR OFFER: FREE!
Your start in a secure LOTO-system, inclu-
ding the purchase of a LabelMax SP3,
VS1 or VX1 is considered, as we say in
German “more than free”.
In addition, if you purchase a MAX
Systems labelling system, you will
receive a 10% special discount on all
LOTO products in the first year.
NEW!
L a b e l M ax
Ou r
series: NEW!
Our masterpiece for simple
and individual labelling!
The labelling systems for mobile use!
• Creates individual and extremely durable signs and markings in • Simply label anywhere - completely independent
no time of the power grid!
• Large selection of ribbons, labels and endless foils in dust-proof • Splash and dust protected (IP 54)
foil cartridge • Certified to US military standard MIL-STD-810G
• High quality color display and simple menu navigation • Robust and mobile - made for outdoor use!
• Incl. easy to use sign software SignMax • Long standby times
You would like to buy a marking system from MAX Systems?
Just contact us. We are happy to help! Phone: +49 (0) 47 63 / 9 45 95 - 0 or E-Mail: info@maxsystems.de
www.maxsystems.eu 9
MSL 1.1 Standard: Lockout Tagout SignMax ID & SignMax PL
»SignMax ID TIP: from the
labels
Creating ax PL
MAX Systems‘ SignMax ID allows you to quickly cre- a x ID a nd SignM
SignM ularly ea
sy
ate LOTO equipment and machinery identifiers. is partic s eries
abelMax
1. Enter machine data and print Identification label with a L and
system
2. Define and record shutdown procedure labelling b e ls.
ted la
3. Done! Call shutdown procedure if necessary and pre-prin
process
Your advantages with the SignMax ID:
Record shutdown - easier than ever
Print and affix markings directly
Overview of all systems and machines
Once created, usable again and again
OFFEgRsy:stems
ellin
Buy lab s
X System
from A
M
e
th
and get
free!
x PL for
SignMa
»SignMax PL
With the SignMax PL you can label and personalize
locks in just a few steps.
1. Enter name
2. Enter company / department
3. Print the label and stick it on the lock
Your advantages with the SignMax PL:
Lock Labels quickly and easily print
Locks are reusable, e.g. when employees
change (as opposed to engraved locks)
QR-Code on the label contains all information
about the lock and allows short term modifica-
tion of the data
List of all locks incl. respective employee in the
SignMax PL
10 Just call us: +49 (0) 47 63 / 9 45 950Expression of Thanks MSL 1.1 Standard: Lockout Tagout
» Many Thanks!
» Vielen Dank!
Thank you for reading this brochure and for ma-
Vielenyour
king Dank, dass
future andSiethat diese Broschüre
of your gelesen
employees sa-
haben
fer. Andund Ihreif Zukunft
even you are und not die Ihrer Mitarbeiter
a customer of MAX
sicherer gestalten
Systems and are notwollen. Und inselbst
interested wenn one,
becoming Sie
kein the
take Kunde von guide
3 point MAX Systems
to heart. sind oder akeiner
Introduce sim-
werden,
ple LOTOnehmen
system Sie sichorganization
to your den 3-Punkte-Leitfaden
so that your
zu Herzen. Führen
employees Sie einaccept,
understand, einfaches
and LOTO-System
hopefully en-
in Ihrem
joy Unternehmen ein, damit Ihre Mitarbeiter
this system.
Ifdieses System
everyone were verstehen,
to experienceakzeptieren und even-
the system and
tuell auch were
everyone ein bisschen
to stick gernto it,haben.
you would also see
Denn anur,
what safewenn
system alleit das System
is! Stay leben und sich
healthy!
alle daran halten, ist es auch ein sicheres System.
Bleiben Sie gesund!
Greetings from Gnarrenburg
Viele Grüße aus Gnarrenburg
Michael Max Meyer
Executive Director
Geschäftsführer MAXMAX Systems
Systems GmbH
GmbH
MAX Systems GmbH
Am Bauhof 12 | D-27442 Gnarrenburg
Phone: +49 (0) 47 63 / 9 45 95 - 0
Fax:
MAX+49 (0) 47GmbH
Systems 63 / 9 45 95 - 11
info@maxsystems.de
Am Bauhof 12 | D-27442 Gnarrenburg
www.maxsystems.eu
Tel.: +49 (0) 47 63 / 9 45 95 - 0
Fax: +49 (0) 47 63 / 9 45 95 - 11
info@maxsystems.de
www.maxsystems.de
www.maxsystems.eu 11SIGN PRINTER
SIGNS & LABELS
WORK SAFETY
MAX Systems GmbH
Am Bauhof 12 · 27442 Gnarrenburg
Phone: +49 (0)47 63 / 9 45 95 - 0
Fax: +49 (0)47 63 / 9 45 95 -11
info@maxsystems.de
www.maxsystems.eu
Reachable by phone:
Monday - Friday: 8:00 a.m - 5:00 p.m
Version: 2019-02 4 052191 519744
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