digitize lockout tagout proceduresDigitize Your Lockout Tagout Procedures In Minutes For Easy Access
Share This
digitize lockout tagout proceduresDigitize Your Lockout Tagout Procedures In Minutes For Easy Access

This article is a beginner’s guide to lockout tagout. It dives into what it is, why it’s important, how it is performed, and other key details!!

Providing a safe work environment should be a top priority for any organization, but especially in industries where employees work with machinery, dangerous equipment, and hazardous energy. One of the most effective ways to promote safety and protect workers in these environments is to implement the safety practice lockout tagout (LOTO).

But what exactly is lockout tagout, and why is it so important? In this article, we will discuss the meaning of LOTO, how it works, why it’s essential, and the regulations that guide its implementation.

Lockout tagout

What is Lockout Tagout?

Lockout tagout (LOTO) is a safety practice used to ensure that machines and equipment are properly shut down during maintenance or servicing work. Its purpose is to protect workers from serious injuries or fatalities by preventing accidental startup or energization of equipment. It involves physically locking power sources and placing warning tags on the machine to alert nearby workers that the equipment is off-limits until the procedure is completed and the equipment is returned to service.

So, when should LOTO be performed? What industries need it? Lockout/Tagout should be used any time there is the possibility of unexpected energization, start up, or release of hazardous energy of machines or equipment that could cause injury and harm to workers. This could apply to workers performing repairs, set up, servicing, inspections, cleaning, and other activities. 

Because of its role in safety, lockout tagout procedures are often implemented in industries that deal with any form of hazardous energy (such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and other energy sources).

Steps For Performing Lockout Tagout

Lockout tagout involves a series of steps that work together to allow machinery to be safely shut down, worked on, and then returned to normal service. Here is a quick overview of the 10 steps of lockout tagout. 

  • Step 1: Prepare for Shutdown: Before even touching the equipment, prepare for the lockout tagout procedure by notifying all authorized and affected workers involved, identifying the sources of energy, and reviewing procedure steps.

     

  • Step 2: Equipment Shutdown: Turn off all power sources and ensure that the machine is fully shut down before moving on.

     

  • Step 3: Isolation of Energy Sources: Isolate the machinery/equipment from all energy sources by turning off circuit breakers, closing valves, or disconnecting mechanical linkages. This will put the equipment in a de-energized state.

     

  • Step 4: Lockout/Tagout Device Application: Once the energy sources have been isolated, have an authorized employee apply your lockout and tagout devices (items such as padlocks, hasps, tags, etc.) to the isolation points. These items will prevent accidental re-energization and provide a safe working environment.

     

  • Step 5: Dissipation of Residual or Stored Energy: Dissipate the stored energy by safely releasing any residual energy or validating that it is securely contained.

     

  • Step 6: Verification of Isolation: Confirm that the equipment is properly isolated and de-energized before beginning maintenance work.

     

  • Step 7: Performing Maintenance or Servicing: Once the isolation is complete and it’s confirmed that the equipment is safe, you can proceed with the actual servicing activities. This step includes tasks such as inspecting, repairing, or replacing components.

     

  • Step 8: Releasing from Lockout/Tagout: Before anything else, notify all affected employees that the lockout tagout devices will soon be removed and then proceed to carefully remove the lockout and tagout devices.

     

  • Step 9: Equipment Restart: Carefully follow the established startup procedures to ensure that the equipment is returned to normal operation safely.

     

  • Step 10: Documentation and Record-keeping: The final step in lockout/tagout procedures is accurately recording all activities related to the LOTO process. This is useful for staying organized, proving compliance, and managing efforts.

     

lockout tagout on a machine

Why is Lockout Tagout Important?

According to OSHA, lockout tagout is estimated to help prevent 120 fatalities and 50,000 injuries every year. This stat highlights how LOTO serves as a critical form of accident prevention in the workplace. 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 lockout tagout 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.

Safety Standards Governing LOTO

There are 2 main safety standards that govern lockout tagout in the US: OSHA 1910.147 and ANSI Z244.1. In this section we will briefly go over the main points of each standard. However, you can access a more in-depth guide for each of the standards by clicking the links above.

In the United States, the Occupational Safety and Health Administration (OSHA) is the primary authority on lockout tagout and workplace safety in general. OSHA provides a detailed guide for lockout tagout in their standard The Control of Hazardous Energy (Lockout/Tagout) 29 CFR 1910.147. This safety code requires employers to:

  • Develop a written LOTO program.
  • Identify all machinery and energy sources requiring lockout procedures.
  • Train employees on proper LOTO procedures.
  • Conduct periodic inspections to ensure compliance.
  • Enforce the use of locks and tags during maintenance or servicing.

OSHA 1910.147 is government backed, meaning that they have jurisdiction and are responsible for handing out fines and violations to organizations that don’t comply with the established safety regulations. As a result, it is imperative to become familiar with and closely follow OSHA 1910.147.

Along with OSHA, the American National Standards institute (ANSI) provides guidance for enhancing LOTO safety in their standard ANSI Z244.1 The Control of Hazardous Energy Lockout, Tagout and Alternative Methods. Similar to 1910.147, this safety standard details how to perform lockout tagout while adding additional information about topic such as: 

  • Best practices for alternative methods of energy control.
  • Recommendations for group lockout and shift changes.

Companies that comply with both OSHA and ANSI guidelines ensure a higher level of workplace safety and avoid costly violations.

lockout tagout

Common Misconceptions

Despite its importance, there are many misconceptions surrounding lockout tagout. In this section we will look at some of the most common misunderstandings about LOTO and set the record straight.

  • Misconception: “Lockout Tagout only applies to electrical energy.”
  • Truth: LOTO applies to all hazardous energy sources including hydraulic, pneumatic, thermal, and mechanical.
  • Misconception: “LOTO is only required for large machines.”
  • Truth: Even small equipment can store dangerous energy and must be locked out properly before having any maintenance or servicing activities performed on it.
  • Misconception: “Using just a tag is enough.”
  • Truth: A lock must always be used in tandem with a tag. The only exception is if the equipment cannot be locked out.

When performing lockout tagout, make sure you are relying on correct information and learning from credible sources. It never hurts to consult a safety standard, experienced coworker, the internet, or trusted articles such as this one to double check.

Conclusion

Lockout Tagout is a critical safety measure that protects workers from hazardous energy during servicing or maintenance on equipment. By following lockout tagout steps, making safety a priority, and complying with OSHA 1910.147/ANSI Z244.1, companies can prevent workplace accidents, protect lives, and maintain compliance.

Note: If your workplace still relies on outdated or inconsistent LOTO procedures, it’s time to improve your program and enhance worker safety. Invest in software to improve your compliance tracking, data history, scheduling, team collaboration, and more!

Simplify Lockout Tagout With Software

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