Lockout Tagout Demystified: Everything You Need to Know to Stay Safe and Compliant

What Is Lockout Tagout?

Lockout Tagout is a control of hazardous energy procedure that involves shutting off and securing machinery or equipment to ensure it cannot be restarted while maintenance or repair is being performed.

 Why LOTO Is Important

• Prevents serious injuries or fatalities due to unexpected machine startups or energy release.

• Required by regulations such as OSHA 29 CFR 1910.147.

• Reduces equipment damage and operational downtime.

• Reinforces a culture of safety and responsibility.

 Types of Hazardous Energy Controlled by LOTO

• Electrical (wiring, circuits)

• Mechanical (moving parts)

• Hydraulic (pressurized systems)

• Pneumatic (compressed air)

• Thermal (extreme temperatures)

• Chemical (stored substances)

 Core Components of a LOTO Program

1. Energy Control Procedures (ECP)

• Step-by-step instructions to shut down and isolate equipment.

• Must be specific to each machine or process.

2. Lockout Devices

• Physical locks that prevent the activation of switches, valves, or levers.

• Only the person performing maintenance should hold the key.

3. Tagout Devices

• Warning tags placed on controls to indicate that equipment is being serviced.

• Used when lockout is not possible but must include the name of the person and the date.

 6 Essential Steps of the LOTO Process

1. Prepare for Shutdown

   • Understand the type and magnitude of energy involved.

2. Notify Affected Employees

   • Inform workers that equipment will be shut down and serviced.

3. Shut Down the Equipment

   • Power off using normal controls.

4. Isolate the Energy Sources

   • Disconnect all energy sources (electrical, hydraulic, etc.).

5. Apply Lockout/Tagout Devices

   • Secure each energy point with a lock and tag.

6. Verify Isolation

   • Try to operate the equipment to ensure it cannot start.

Never assume the equipment is de-energized—always test to verify.

Training and Responsibilities

• Authorized Employees: Apply and remove LOTO devices; perform maintenance.

• Affected Employees: Operate or work near the equipment; must understand the procedure.

• Other Employees: Should be aware of LOTO policies and respect tags and locks.

Training must be initial, task-specific, and periodic to maintain awareness and compliance.

Periodic Inspections and Compliance

• Regularly inspect energy control procedures at least annually.

• Ensure procedures are up-to-date and employees are following them.

• Keep records of inspections and corrective actions.

Common LOTO Mistakes to Avoid

• Using tags without locks when locks are possible.

• Sharing lock keys among multiple workers.

• Failing to verify isolation before starting work.

• Restarting equipment without confirming everyone is clear.

Final Thoughts

Lockout Tagout saves lives, it's that simple. Implementing a thorough, well-communicated, and consistently followed LOTO program is not only a regulatory requirement but a fundamental aspect of workplace safety. Remember: every lock and tag represents a life.