Alternative Control Measure Compliance Services
Ensure Safe and Compliant Control of Hazardous Energy
While Lockout/Tagout (LOTO) remains the industry standard for controlling hazardous energy, there are many situations where Alternative Control Measures (ACMs) are both permitted and necessary—particularly in production, setup, or maintenance environments where full lockout would be impractical.
DAK Machine Safety provides expert guidance to ensure your ACMs are implemented safely, compliantly, and effectively, in accordance with ANSI/ASSP Z244.1 and OSHA best practices.
What Are Alternative Control Measures (ACMs)?
Alternative Control Measures are engineered for certain tasks and work in parallel with other means of energy control such as full or partial lockout/tagout. Mainly Task, Need and Risk assessment dependent.
Examples of some ACMs when properly implemented with a Risk Assessment are:
- Safety interlocks
- Presence sensing devices
- Two-hand controls
- Enabling switches
- Trapped key systems
DAK’s ACM Compliance Services
We help manufacturers and facility managers ensure that every ACM is properly engineered, documented, and validated and personnel understand which tasks are allowed to be performed under ACM per machine. Our services include:
Assessment of ACM Applicability
We evaluate whether the use of ACMs is justified and allowed under ANSI Z244.1 and OSHA 1910.147 exception provisions by:
- Review the Risk Assessment Report, machine tasks and various energy types (gravitational, stored, springs, Radiation, Fluid Power, etc.)
- Identify the tasks needed to be performed on the machine that require power or partial power and which does not. Understand what partial power is needed on those machines.
- Reviewing existing LOTO procedures for overlap and gaps
Engineering & Safeguard Design
We confirm that any ACMs used rely on validated safeguarding systems that achieve an acceptable level of risk reduction, including:
- Design of safety circuits (Category and PL verification)
- Specification of interlocks, scanners, solenoid valves, and relays
- Integration with safety PLC logic and reset architecture
- Provide Exclusive Control and can’t be defeated nor bypassed
ACM Procedure Development
We create clear, machine specific ACM documentation that meets ANSI Z244.1 requirements:
- ACM description and justification
- Approved tasks and authorized personnel
- Safety systems required to enable the ACM
- Required inspections and verification steps
- Operator training and signage needs
Each procedure is written in plain language with visual aids and placed next to its respective device for ease of personnel on the machine to review and verify.
System Validation & Functional Testing
DAK performs full validation of ACM safety systems to confirm:
- All devices operate as expected during task execution
- Energy sources are isolated or rendered safe
- Interlocks and control logic properly prevent unexpected startup
- Forced faults and bypass conditions are safely managed
- The ACM procedure and system can withstand misuse or failure
- Safety PLC checksum CRC has been documented along with the date and time for each test performed
A final Report is provided for internal compliance tracking and external audit preparation.
Why Use DAK for ACM Implementation?
Deep knowledge of ANSI Z244.1, OSHA 1910.147, and functional safety standards Cross-discipline mechatronics, robotics, engineering experience in electrical, mechanical, pneumatic, and hydraulic safety.