WHS Hazardous Energy Control Standard Global

*Standards are not actioned at a site level*

WHS Hazardous Energy Control Standard Global

Published: 9-May-24
Effective: 9-May-24
Version: 5
Doc ID: 32130

Contents
1. Purpose ............................................................................................................................................................................................. 2
2. Applicability ....................................................................................................................................................................................... 2
3. Terms and definitions ....................................................................................................................................................................... 2
4. Responsibilities.................................................................................................................................................................................. 2
5. Requirements .................................................................................................................................................................................... 2
6. Competence and awareness ............................................................................................................................................................. 5
7. Audits, inspections, and evaluations ................................................................................................................................................. 5
8. Continual improvement .................................................................................................................................................................... 5
9. Reporting ........................................................................................................................................................................................... 5
10. Documented information.................................................................................................................................................................. 5
11. External References .......................................................................................................................................................................... 6
12. Change management and document history .................................................................................................................................... 6
13. Appendix ........................................................................................................................................................................................... 7
Appendix A: Examples of lockout/tagout equipment (informative) ..................................................................................................... 7
Appendix B: Risk assessment for alternative methods (informative) ................................................................................................... 8

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1. Purpose
The purpose of this standard is to establish safe work practices for the control of hazardous energy and ensure the effective
implementation, operation, and recordkeeping of Amazon’s lockout/tagout (LOTO) program. During a LOTO procedure, it is
important to ensure protection against the unexpected energization, start-up, or release of stored energy from any machine or
equipment.

2. Applicability
PERSONNEL APPLICABILITY*
Non-Yellow Badge Other: Onsite 3P
Blue-Badge Yellow-Badge Green-Badge Visitors
Contractor RME
*for questions on personnel applicability, see badge descriptions here

In this standard, the words "facility/operation" or "site" may be referenced but the concepts conveyed by this standard apply across
all levels of Amazon.
This standard is not intended to supersede or replace any applicable regulatory requirements. In case of conflict, the most stringent
requirements shall prevail.

3. Terms and definitions

Refer to the Global WHS Glossary.
• Exclusive control - the authorized worker has the authority to and is continuously in a position to prevent (exclude) other
individuals from re-energizing the machine or equipment during servicing or maintenance activity

4. Responsibilities
Refer to the WHS Management System (WHSMS) Standard Global.

5. Requirements
5.1 Written hazardous energy control program (HECP)
Plan, develop, implement, and maintain a written Hazardous Energy Control Program (HECP) that addresses the following, at a
minimum:
1. roles, responsibilities, and accountabilities for all personnel who play a role in implementing the site HECP;
2. risk assessment;
3. safe work procedures for hazardous energy control;
4. energy isolating devices or equipment;
5. competence and awareness;
6. performance evaluation; and
7. continual improvement.

5.2 Roles, responsibilities, and accountabilities

Assign, communicate, and document roles, responsibilities, and accountabilities of all personnel involved in the planning and
implementation of the HECP, including but not limited to facility/operations top management, WHS managers or business-assigned
WHS representatives, engineering, maintenance, facilities, supervisors, competent persons, and associates.
5.2.1 Top management/leadership and commitment
Refer to the WHS Management System (WHSMS) Standard Global.

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5.2.2 Worker participation and consultation
Ensure participation by, and consultation with, all affected workers on the management and control of risks associated with their
work, including communication methods and training. Refer to the WHS Management System (WHSMS) Standard Global.

5.3 Risk assessments

In conformance with the risk assessment requirements in the WHS Risk Management Procedure Global, a competent person shall
facilitate the process for performing risk assessments of all hazardous energy and control risks, ensuring a broad range of persons
are involved, including representatives from those persons affected by each hazard. A technical SME may need to be involved. Risk
assessments shall draw upon information from associate and other worker participation and consultation as well as previous risk
assessments of operations that have taken place. Risk assessments shall be reviewed regularly to ensure that they remain fit for
purpose.

5.4 Safe work procedures for hazardous energy control

Develop safe work procedures to prevent injury from uncontrolled hazardous energy which ensure:
1. isolation of all hazardous energy sources (such as, zero energy state), prior to initiation of work on equipment or machinery;
2. each LOTO-authorized worker has individual locks, each with only one distinct key kept under control of the owner
throughout work;
3. LOTO devices are only removed by the individual applying the device. Unauthorized removal or tampering with energy
control devices is prohibited unless following a dedicated process (see sections 5.4.5 and 5.4.6), and failure to follow the
requirement shall result in progressive disciplinary actions;
4. a procedure for shutting down equipment and restarting after locks have been removed is established, which shall include
at a minimum notifying associates and RME, removing LOTO devices, and verification of normal operations;
5. equipment-specific LOTO procedures are established as per local requirements;
6. exceptions and/or exemptions to LOTO per local requirements are documented; and
7. special circumstances safe work procedures are established per local requirements (see sections 5.3.1 through 5.3.6).

5.4.1 Alternative methods procedure

Alternative methods are methods developed for energy control and protection of workers for situations where complete LOTO
cannot be used. Prior to utilizing alternative methods, a risk assessment shall be completed (example in Appendix B), including
consideration for country specific regulations.
In general, alternative methods may be used for:
1. tasks that are routine, 1 repetitive, 2 and integral 3 to the process and not servicing and/or maintenance activities (e.g.,
minor tool changes and/or adjustment, set-up, clearing simple jams, testing, part location, and cleaning);
2. tasks that do not require that the machine, equipment, process, or circuit be taken out of the operational mode to
accomplish them; and
3. tasks required to sustain machine, equipment, process, or circuit continuity within the nominal performance range and
output quality. This typically occurs when the machine, equipment, process, or circuit is operating normally and the
need for periodic service is predictable based on operating experience and product demands.
Alternative methods shall not be used if:
1. workers must bypass or remove guards or safety devices, or otherwise place any body part in the machine, equipment,
process, or circuit operating area;
2. a written alternative method is not available; or
3. task-specific training has not been provided.

1 the activity is a regular course of procedure and in accordance with established practices
2 the activity is regularly repeated as part of the production process
3 the activity is essential to the production process

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5.4.2 Group LOTO procedure
A group LOTO procedure is required when more than one associate is engaged in the servicing and/or maintenance activities. Each
member of the group shall affix their personal LOTO device and must be provided with the same level of control and energy isolation
verification that they would be provided in an individual hazardous energy control scenario.
Where one or more energy-isolating devices cannot accommodate multiple locks, the following may be used:
1. multiple lock application using lock devices (hasps) that accommodate several individual LOTO locks; or
2. lock boxes: LOTO supervisor applies their lock to each energy source; the padlock keys are placed inside the lock box;
and all authorized workers servicing and/or maintaining the machine, equipment, process, and circuit secure and
attach their individual LOTO locks to the box.
In the servicing and/or maintenance of sophisticated and complex process equipment, adaptation and modification of normal group
LOTO procedure may be necessary to ensure the safety of the associates.
5.4.3 Shift or personnel changes procedure
Develop a procedure to ensure that equipment retains LOTO during shift turnover or while equipment is needed to be disabled due
to being out of service.
5.4.4 Use of tagout device alone procedure
1. Conduct a risk assessment for any device not capable of accepting a lock, specifying the approved alternative methods
to ensure safe access;
2. Take additional measures to demonstrate full associate protection, such as removing an isolating circuit element,
blocking a controlling switch, opening an extra disconnecting device, or removing a valve handle to reduce the
likelihood of inadvertent energization;
3. Ensure that the tagout device has been applied; and
4. Train associates to recognize the limitations of tags.

5.4.5 Abandoned locks and tags procedure

When the authorized worker who applied the LOTO device is not available to remove it, that device may be removed under the
authorization of the facility/operation leadership after all possible attempts have been made to locate the worker.
Document the attempts to locate the worker and the fact that someone other than the worker removed the lock. Notify the signer
of the tag upon their return and prior to resuming work that the LOTO has been released. If authorized workers cannot be reached
to inform them of the removal of their lock prior to the start of their next shift, temporarily remove badge access to the building
until the worker is informed of the removal of the LOTO.
5.4.6 Temporary removal of lockout devices
Establish a process for temporary removal of LOTO devices.
5.4.7 Out of service
Develop a procedure to ensure that equipment is locked out due to being out of service.

5.5 Energy-isolating devices or equipment

Use LOTO procedures on all energy-isolating devices capable of being locked out. An energy-isolating device is capable of being
locked out if it has one of the following:
1. a hasp or other means of attachment to which, or through which, a lock can be affixed;
2. a locking mechanism built into it; or
3. a means to achieve lockout without the need to dismantle, rebuild, or replace the energy-isolating device, or permanently
alter its energy control capability.
5.5.1 LOTO devices
Ensure that LOTO devices or equipment used to isolate, secure, block, and/or otherwise control the condition of the equipment or
machinery meet the following requirements:
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1. They are made readily available in adequate quantities to meet the LOTO needs of the facility/operation;
2. They are controlled by one person only; and
3. The design and construction of LOTO devices are:
a. durable and capable of withstanding the environment to which they are exposed for the maximum period of time
that exposure is expected;
b. standardized only for LOTO use in in color, shape, size, or specific markings; and additionally, in the case of tagout
devices, print and format shall be standardized; and
c. substantial enough to prevent inadvertent or accidental removal without the use of excessive force or destructive
techniques e.g. with the use of bolt cutters.
See Examples of Lockout/Tagout Equipment (Informative) for example LOTO devices.
5.5.1.1 LOTO tags
Ensure LOTO tags visually display a prominent warning of the hazard and are identifiable to the person applying the tag.
Table 1: Recommended specifications for LOTO tags
Tag type Recommended specification
LOTO Tag • Affixed to every LOTO lock where active maintenance and/or servicing activities are taking place
• “Danger” header followed by “Do Not Operate”
• Have an area to document the date and name of the authorized individual applying the device
Out-of-Service Tag • Affixed to equipment indicating an “out of service” or inoperable condition
• “Caution” header followed by “Do Not Operate”
• Have an area to document the date and name of the authorized individual applying the device

5.5.1.2 LOTO locks

Each individual worker shall control their own lock or tag. In a situation where more than one person is involved in the LOTO
process, the group LOTO process will be followed (see section 5.4.2).
5.5.1.3 Other lockout devices
Ensure that other lockout devices (e.g. valve covers, handle covers, circuit breaker covers, hasps) are capable of accepting a lock
and/or tag. These devices shall only be used for hazardous energy control and identifiable to the person applying the lock.
5.5.1.4 Inspection
The user of the LOTO equipment shall inspect, before each use, LOTO equipment to ensure it remains in good condition.

6. Competence and awareness

See the associated geo-specific procedure for additional guidance related to audits, inspections, and evaluations.

7. Audits, inspections, and evaluations

See the associated geo-specific procedure for additional guidance related to audits, inspections, and evaluations.

8. Continual improvement
See the associated geo-specific procedure for additional guidance related to continual improvement.

9. Reporting
See the associated geo-specific procedure for additional guidance related to reporting.

10. Documented information

See the associated geo-specific procedure for additional guidance related to documented information.

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11. External References

• ISO 45001:2018 Occupational health and safety management system
• “OSH Answers Fact Sheets – Lockout Tagout” Last updated 11 Jan 2017.
https://www.ccohs.ca/oshanswers/hsprograms/lockout.html

12. Change management and document history

Table 3: Document change history
Version Description Published Effective Next review
1 Initial document 1-Aug-17 1-Aug-18 1-Aug-20
2 1. Scope updated to exclude Whole Foods. 22-Jun-18 1-Aug-18 1-Aug-20
2. Author and technical reviewer names corrected;
3 Changes were made to the following sections due to an internal GEMS 7-Mar-19 7-Mar-19 1-Aug-20
review against ISO45001:2018 requirements
1. Section 4 and 12- Updated glossary hyperlink.
2. Section 6.2 -Changed “define” to “Assign ,communicate and document
roles, responsibilities, and accountabilities”
3. Section 6.2.2- Added “participation” under Worker Participation and
Consultation.
4. Section 6.3- Included consultation and participation of workers facilitated
by an SME.
5. Section 12- Added reference to ISO 45001:2018
6. Removed gap assessment table (previously Appendix A); it is now
available as Audit Protocols on GEMS Self-Assessment Tool- Gensuite.
4 1. Section 6.3 bullet points a), b) and d) - reflect change from WHS Risk 10-Feb-20 10-Feb-20 1-Aug-20
Management Standard Global (GEMS 106). Included terminology - ‘health
and safety’ hazard and ‘environmental’ aspect.
2. Examples of H&S hazards added as footnote.
3. Due to organizational scope change, the following changes are made:
hyperlinks added for all GEMS Standards, and "EHS" in text changed to
"WHS".
4. Section 12: References. Hyperlinks to standards, tools and guidance,
audit protocol added as text.
5 1. Updated to current L2 template. 9-May-24 9-May-24 9-May-27
2. Removed labeling of energy isolating devices.
3. Consolidated plug and cord and exceptions to LOTO as establishing
general exceptions per local requirements under safe work
procedures.
4. Generalized shutdown and startup requirements under safe work
procedures.
5. Consolidated equipment-specific LOTO procedures per local
requirements under safe work procedures.
6. Generalized requirements for procedure for shift or personnel
changes.
7. Generalized requirement for temporary removal of lockout
devices.
8. Removed contractor management due to coverage under separate
Standard.

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13. Appendix
Appendix A: Examples of lockout/tagout equipment (informative)

a. An equipment-isolating device b. Placement of LOTO lock, tag and LOTO c. Group lockbox
device, i.e. hasp, on an energy-isolating device
on a circuit breaker [Ref:
http://www.totalaccess.co.uk/Equipment/Con
fined-Space-Equipment/Lockout-Tagout]

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Appendix B: Risk assessment for alternative methods (informative)
Location: __________________
Assessed by: _________________________
Date: _________________________
Project / Process / Task description: _________________________________________________________
Tool/Equipment Used: ________________________________________

Before Risk Reduction After Risk Reduction LOTO Required? Actions and
Yes or No Responsibilities
Location of Hazard Control Measures
hazard or Description to be taken
task (Alternative

Likelihood of occurrence

Likelihood of occurrence
Possibility of avoiding or

Possibility of avoiding or
performed limiting harm Methods)

limiting harm
Risk Level

Risk Level
Exposure

Exposure
Severity

Severity

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