Lockout-Tagout Basics Every Maintenance Team Should Follow
Core LOTO steps to prevent unexpected equipment start-up during servicing.
Lockout-tagout (LOTO) is a procedure that makes sure machines cannot start or release stored energy while someone is working on them. It is one of the basic controls against serious injury during maintenance.
What LOTO is
Lockout means fitting a personal lock on the energy-isolating device, such as a breaker, valve or disconnect, so it cannot be operated. Tagout means attaching a tag that says who is working and why. Where a lock can be fitted, the lock is the stronger control.
The basic steps
- Prepare: identify the machine and every energy source: electrical, pneumatic, hydraulic, gravity, springs, heat.
- Notify: tell everyone affected that the machine will be shut down.
- Shut down using the normal stop procedure.
- Isolate each energy source at its isolating device.
- Lock and tag each isolating point. Each worker uses their own lock.
- Release stored energy: bleed pressure, discharge capacitors, block raised parts.
- Verify: try to start the machine and check with a tester that it is dead, then return controls to off.
Removing the lock
Only the person who fitted a lock removes it. Before restoring power, check that tools are removed, guards are back on and everyone is clear, and tell the people affected.
Common mistakes
Relying on the stop button instead of true isolation, skipping the verification step, forgetting stored energy, sharing locks, and not locking all the sources are the usual failures. Written procedures for each machine and regular training reduce them.
Follow your site rules
Use the procedure required by your company, your site and the applicable regulations. This article is a general introduction, not a replacement for your safety procedures or for training.
Key Takeaways
- Isolate, lock, tag, release stored energy, then verify.
- Each worker uses a personal lock.
- Follow the written site procedure and training.
This article is general guidance. For a recommendation for your own application, contact our engineering team. Industrial tools and safety supplies →