Agents are often the first point of connection between commercial clients and the safety resources that help prevent serious workplace injuries. While many employers believe their safety programs are “good enough,” some of the most severe and costly workers’ compensation claims stem from failures to control hazardous energy—incidents that proper Lockout/Tagout (LOTO) procedures can prevent.

Helping Agents - Strengthen Accounts, Reduce Losses, and Deliver Added Value Through Forestry Mutual’s Loss Control Support

For agencies working with wood products operations—or any environment involving heavy or energized equipment—LOTO presents an opportunity to open an important safety conversation. When approached thoughtfully and supported by the right resources, that conversation can help reduce exposure while reinforcing the agent’s role as a trusted advisor—supported by specialized loss control expertise.

Unlike more visible safety issues, LOTO failures often go unnoticed until something goes wrong. Equipment starts unexpectedly. Stored energy releases without warning. An employee is injured during what was assumed to be a routine task. When these incidents occur, the consequences are rarely minor and almost always preventable.

LOTO: A Critical Safety Conversation

According to OSHA, nearly 3 million U.S. workers service or maintain equipment where hazardous energy is present. Proper LOTO practices prevent an estimated 60,000 injuries each year. Despite this, many employers still lack formal procedures—or rely on shortcuts that expose employees and the business to serious risk.

When LOTO is skipped or improperly performed, injuries are rarely minor. These incidents frequently result in amputations, crushing injuries, permanent disability, or fatalities—the types of claims that significantly impact experience modification factors, disrupt long-term pricing stability, and may even affect an employer’s ability to secure coverage.

From an agent’s perspective, these losses extend beyond the individual account. High-severity claims can influence underwriting decisions, affect carrier appetite, and introduce long-term challenges across the book of business. Helping clients recognize LOTO gaps early—and connecting them with the right support—is a practical way to reduce these downstream impacts.

OSHA Context: Why LOTO Continues to Be a Focus Area

OSHA’s Lockout/Tagout standard (29 CFR 1910.147) has been in place for decades, yet hazardous energy control violations continue to rank among the most frequently cited serious safety issues in manufacturing and industrial environments.

This persistent enforcement focus reflects what investigations repeatedly show: LOTO failures are rarely the result of intentional disregard. More often, they stem from incomplete procedures, inconsistent training, or informal practices that develop over time—especially in operations with aging equipment, production pressures, or employee turnover.

For employers, OSHA citations are only part of the equation. The greater exposure lies in the injuries that occur when procedures aren’t followed consistently. A single lapse—such as assuming equipment is fully de-energized or relying on a power switch instead of proper isolation—can lead to catastrophic outcomes.

Understanding this context allows agents to introduce LOTO as more than a compliance topic. It becomes a broader discussion about operational discipline, employee protection, and long-term financial stability—one that is best supported by specialized loss control expertise.

How Agents Can Spot Potential LOTO Gaps

Identifying potential LOTO issues doesn’t require agents to be technical safety experts. In many cases, recognizing when something doesn’t look right is enough to prompt a deeper review by Forestry Mutual’s Loss Control team.

During prospect visits or account reviews, agents may encounter indicators that a LOTO program needs further evaluation:

1. No Written Procedures
   Equipment-specific lockout instructions should be documented—not left to verbal reminders or informal practices.

2. Shared Locks or Keys
   Shared locks or master-key systems weaken accountability and increase exposure.

3. No Annual Program Review
   OSHA requires periodic inspections of LOTO programs, yet many employers have never completed one.

4. Missing Training Records
   Operators, maintenance staff, and affected employees must receive documented training.

5. Over-Reliance on Power Switches
   Electrical shutoff alone is insufficient. Hydraulic, pneumatic, thermal, chemical, and stored energy sources must also be controlled.

When these indicators are present, the employer may face elevated risk—and may benefit from further evaluation supported by Forestry Mutual’s Loss Control professionals.

Common LOTO Mistakes in the Wood Products Industry

Wood products operations present unique LOTO challenges due to heavy machinery, multiple energy sources, and production-driven environments. Many LOTO breakdowns occur not because safety is ignored, but because everyday practices gradually drift.

Treating Jam Clearing as “Normal Operations”
Clearing jams on saws, conveyors, or chippers is often viewed as routine. In reality, these tasks frequently expose employees to hazardous energy and should trigger full lockout procedures.

Focusing Only on Electrical Energy
Disconnecting power does not eliminate all risk. Stored mechanical, hydraulic, or pneumatic energy—such as tensioned belts or pressurized lines—can remain dangerous even after equipment is powered down.

Using Generic Procedures Across Multiple Machines
A single LOTO procedure applied to different machines overlooks unique energy sources and shutdown steps. Equipment-specific procedures are critical for consistency.

Informal Lock Removal Practices
Removing another employee’s lock—even with good intentions—can result in premature startup and serious injury. Clear rules and supervisory oversight are essential.

Communication Gaps Between Maintenance and Operations
Misunderstandings about when equipment is locked out or returned to service are a frequent contributor to incidents.

These challenges are common in wood products operations and are best addressed through a collaborative approach involving the agent, the employer, and Forestry Mutual’s Loss Control team.

Talking to Clients About LOTO: Key Concepts to Emphasize

When LOTO becomes part of a client conversation, agents can focus on core principles—without needing to deliver technical instruction. These elements, supported by Forestry Mutual’s Loss Control guidance, form the foundation of an effective program:

• Clear Rules for When LOTO Applies
  Distinguishing routine operations from servicing or maintenance activities that require lockout.

• Identification of All Energy Sources
  Addressing electrical, hydraulic, pneumatic, thermal, chemical, and stored energy.

• Proper Energy-Isolating Devices
  Ensuring disconnects, breakers, and valves are clearly identified, locked, and tagged.

• Communication With Affected Employees
  Making sure operators and nearby workers understand when lockout is in place.

• Correct Locking and Tagging Procedures
  Requiring each employee servicing equipment to apply their own lock.

• Verification of Zero Energy
  Testing equipment before work begins to confirm energy has been fully controlled.

• Safe Return to Service
  Using structured startup procedures to prevent secondary injuries.

• Training and Annual Review
  Reinforcing procedures through ongoing training and periodic program evaluation.

Why This Matters: The Business Case

A strong LOTO program helps:

• Reduce Loss Frequency and Severity
  Preventing catastrophic injuries supports more stable experience mods and pricing.

• Strengthen Client Relationships
  Employers value guidance that helps them operate safely and sustainably.

• Differentiate the Agency
  Connecting clients with meaningful safety resources elevates the agent beyond a transactional role.

• Protect the Book of Business
  Severe losses can affect carrier eligibility; prevention helps preserve long-term partnerships.

By leveraging Forestry Mutual’s Loss Control services, agents can strengthen accounts while relying on carrier-backed expertise to address complex safety issues.

How Forestry Mutual Supports Agents and Their Clients

Forestry Mutual’s Loss Control team serves as an extension of the agent’s toolkit, working alongside agents and their clients to:

• Conduct LOTO program evaluations

• Provide onsite safety training

• Assist in developing written procedures

• Support annual program reviews

• Help reduce exposures before injuries occur

This support allows agents to bring meaningful safety value to client conversations—without needing to be technical specialists. Loss Control services are available to you as part of Forestry Mutual’s workers’ compensation coverage.