lockout tagout devicesTools of Safety: A Practical Guide to Lockout Tagout Devices
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lockout tagout devicesTools of Safety: A Practical Guide to Lockout Tagout Devices

This article an overview of the various industries that use lockout tagout procedures to ensure safety and explains how it is incorporated.

Safety should always be a priority in the workplace; however, it is especially significant in industries that involve hazardous energy (such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources). Workplace environments that deal with these various types of energy rely on lockout tagout procedures to ensure that workers can safely perform their duties and maintain the operational integrity of machinery/equipment. 

Lockout tagout procedures serve as a critical safety barrier which allows workers to conduct maintenance and servicing on equipment with hazardous energy sources. While LOTO is vital across many sectors, certain industries depend on it more heavily due to the complexity of their machinery, frequency of maintenance, and potential for serious injury if procedures are not followed.

Whether you’re new to lockout tagout or simply looking to better understand the workplace safety requirement, this is an article for you. Follow along as we explore some of the most common industries that incorporate lockout tagout, how they apply LOTO, and the unique challenges the face in controlling hazardous energy.

lockout tagout industries

Lockout Tagout Industries

Lockout tagout ensures that machines are properly shut down and isolated before work is performed on them. This helps prevent any unexpected startup or release of hazardous energy. On the surface, lockout tagout can seem like a niche safety measure. However, it is necessary in just about any industry that utilizes large equipment or uses powerful energy to create the product or perform a service. 

Industries where LOTO is commonly used:

  • Manufacturing
  • Food Manufacturing/Processing
  • Public Utilities/Energy
  • Oil and Gas
  • Construction
  • Warehouses 
  • Chemical Processing 
  • Other Industries

A Brief Overview of Each

Now, let’s do a deeper dive into the industries mentioned above to analyze the distinct role that lockout tagout plays in each sector and how it is implemented to safeguard workers, equipment, and property.

The manufacturing industry is one of the most common users of lockout tagout procedures. This is because most manufacturing plants use large and powerful machinery to perform their processes. 

From automotive manufacturers to product assembly lines, manufacturing settings generally rely on machines and equipment that require LOTO to prevent accidental startups during repairs, maintenance, and cleaning activities. With machine changeovers and servicing needs, a well-structured LOTO program is essential for worker protection and OSHA compliance in the manufacturing industry.

Food manufacturing and processing facilities deal with fast-moving conveyors, mixers, slicers, and automated packaging equipment. In order to meet hygiene standards, these machines have to be regularly cleaned and maintained. Lockout tagout procedures help to securely de-energize food/drink processing equipment so that it can be properly cleaned, serviced, or swapped out. 

Generally, the food and beverage processing industry requires more frequent use of lockout tagout than others to meet the strict sanitation requirements of health codes. This requires coordination across shift changes and various teams (i.e sanitation and maintenance personnel) to ensure safety for both workers and product consumers.

The utilities/energy industry powers homes by providing electricity, gas, water, and renewable energy to families across America. While these resources are necessary for day to day life, they can be dangerous to provide. In fact, all of them involve high-voltage or high-pressure systems where hazardous energy is a serious concern. 

On any given day, workers may perform maintenance on transformers, pipelines, or turbines, all of which require isolating energy sources before work can begin. As a result, lockout tagout is crucial for safety within this industry. 

Failure to lock out equipment can lead to fatal consequences, which means that LOTO programs here are critical and should be highly regulated with thorough training and detailed inspection routines.

From petroleum extraction to processing, virtually all aspects of oil and gas operations rely on lockout tagout for controlling dangerous energy sources. After all, hefty equipment is required to obtain crude oil, transport it, refine it, and then distribute it. For this reason, lockout tagout is an essential element of safety in the oil and gas industry. LOTO ensures that equipment can be well maintained, even in these high-risk environments.

Construction is another industry with a great need for lockout tagout. In construction, especially in large-scale projects, workers encounter a wide range of powered equipment and temporary energy systems. From cranes and elevators to electrical panels and compressors, controlling energy sources during setup or repair is essential. 

Due to short uses of equipment, workers sometimes dismiss the need for LOTO in this industry; however, that is a practice that could seriously backfire. Neglecting to control hazardous energy sources can lead to severe injury or damage. 

In order to make LOTO easier, portable lockout tagout devices are often used in the field. Users just have to remember to coordinate well, especially when subcontractors are involved. OSHA requires that all affected workers be notified and protected when equipment is locked out, and that still applies in construction situations.

Modern warehouses use a variety of automated equipment such as conveyor systems, palletizers, and sorting machines. Though these machines are helpful, they can be dangerous if not properly secured during efforts to replace parts, unjam equipment, or perform other servicing tasks. LOTO procedures can prevent sudden movements or energy releases, which allows warehouses to use these powerful machines without any worries about them causing harm. 

Note: With multiple shifts and fast-paced operations, it’s important for warehouses to implement group LOTO practices and keep procedures easily accessible for all employees.

Chemical plants deal with a variety of equipment requiring LOTO procedures including complex piping systems, mixing equipment, and high-pressure reactors. Here, hazardous energy may include not just electrical or mechanical sources, but also chemical reactions or thermal energy.

In this high-risk industry, LOTO is used to isolate equipment before cleaning, inspection, or repairs—especially when hazardous substances are involved. While lockout tagout is significant in every industry it is used for, it is especially vital for chemical processing as it prevents potentially catastrophic chemical reactions.

Lockout tagout is necessary in any industry where machinery and equipment are used, especially those with potential for sudden energy release during maintenance. 

Though we’ve gone over the most prominent industries that use LOTO, there are many unnamed industries that use it on a regular basis. For example, LOTO is used to promote safety in paper processing mills, healthcare facilities, and even on college campuses. This goes to show that it is advantageous to be familiar with lockout tagout no matter what industry you work in. Understanding safety on a more intricate level serves you and those around you.

locked out energy source

Why Lockout Tagout is Essential in These Industries

According to OSHA, lockout tagout is estimated to help prevent 120 fatalities and 50,000 injuries every year. While this stat isn’t industry specific, it highlights how LOTO serves as a critical form of accident prevention in the workplace across the board. Lockout tagout may seem like a non-consequential item on your checklist, but the numbers show that it is a lot more than that.  

While LOTO is primarily meant to prevent worker injuries, it can also help avoid other profound problems including: 

  • Equipment Damage – Accidental equipment startups can result in broken machinery or operational failures.
  • Compliance Violations – Failure to correctly follow lockout tagout procedures can lead to heavy OSHA fines and penalties.
  • Workplace Productivity Loss – Injuries and equipment damage result in downtime, costly repairs, and legal issues.

As per OSHA reports, failure to control hazardous energy is consistently one of the top causes of workplace injuries and deaths, making LOTO an essential safety practice. Though lockout tagout contributes a little something different for each industry it’s used in, it is always a beneficial contribution.

Streamline Lockout Tagout With Software

No matter what industry you are in, lockout tagout software can help make the process much easier.

Our LOTO software has been developed over the last 30 years and is specifically designed to help you write procedures, manage a LOTO program, and perform lockout tagout in a way that is easy, efficient, and effective.

Want to learn more about what our LOTO software can do and how it can make your job easier? Schedule a demo to talk with one of our specialists.

lockout tagout software

Conclusion

Lockout tagout is a crucial safety measure that protects workers across a wide range of industries from hazardous energy. It ensures that workers can safely de-energized machinery and work on it during maintenance and servicing, which helps to meet compliance requirements, prolong the lifespan of equipment, and reduce the risk of any accidents occurring.

Whether in manufacturing, construction, or chemical processing, organizations that prioritize strong lockout tagout programs not only meet safety standards but also build a culture of accountability, responsibility, and care. As industries continue to adopt automation and advanced technologies, lockout tagout remains a timeless safeguard in the evolving workplace.

For more information about how you can revolutionize your approach to safety with lockout tagout software, click the link here.

industries that use lockout tagout