Step 8 - Alternative Method

Lockout/Tagout is the primary method for controlling hazardous energy during servicing, maintenance and repair where workers may be exposed to unexpected start-up, movement or the release of stored energy. It remains the preferred and most effective means of achieving a zero-energy state.

In limited circumstances, certain routine, repetitive and production-integral tasks may be performed using a formally assessed Alternative Method — but only where full lockout is not practicable and effective protection from hazardous energy can be demonstrated.

New Zealand health and safety legislation requires risks to be eliminated so far as is reasonably practicable and, where elimination is not reasonably practicable, minimised using the most appropriate and effective control measures. This includes prioritising isolation and engineering controls. An Alternative Method must therefore be supported by a documented risk assessment and effective controls appropriate to the task.

An Alternative Method is not a shortcut or a matter of convenience. It requires engineered safeguards, defined controls, worker training and formal approval. The approach is consistent with the machinery risk-reduction and safeguarding principles of AS/NZS 4024 and the Alternative Method framework of ANSI/ASSP Z244.1. If adequate protection cannot be demonstrated, full Lockout/Tagout must be applied.

Access the evaluator below to determine whether your activity meets the required criteria.

To support the safe use of an Alternative Method, LockoutHQ provides practical templates to help you assess, document, authorise and manage each approved activity.

Use the Risk Assessment to determine whether equivalent protection can be achieved, the Safe Work Procedure to document how the activity must be performed, and the Authorised Worker Register to record who is trained and authorised to perform it. Together, these resources provide a structured and traceable approach to managing Alternative Methods and ensuring they remain properly controlled and reviewed.

Complete or update the register whenever a worker is formally authorised to perform an Alternative Method activity, when their scope of authorisation changes, or following refresher training or revalidation. Only workers listed as current and authorised should perform the applicable Alternative Method activity.

Complete this Alternative Method Safe Work Procedure whenever an activity has been formally assessed and approved for use under an Alternative Method. The procedure should document the specific task, hazards, engineered safeguards and other controls, authorised personnel, and the step-by-step method required to perform the activity safely. Review and update the procedure whenever the task, equipment, hazards or control measures change.

Complete this assessment before approving any activity for use under an Alternative Method. The assessment should demonstrate that the proposed controls provide effective protection from hazardous energy for the specific task and conditions assessed. Review the assessment whenever the task, equipment, hazards or controls change, or where an incident, near miss or other evidence indicates the existing controls may no longer be effective.

Created with

Step 8 - Alternative Method

Introduction

Resources

Alternative Method Authorised Worker Register

Alternative Method Safe Work Procedure

Alternative Method Risk Assessment