Use this guide to help lead a discussion with employees on the importance of understanding and following lockout/tagout procedures to reduce the risk of injury during maintenance or servicing of machines or equipment.
What is lockout/tagout?
Lockout/tagout is a safety procedure used to protect workers by preventing the unexpected energization or startup of machinery and equipment, or the release of hazardous energy during maintenance activities or repair work.
Lockout: Securing an energy isolating device (like a switch or valve) with a lock controlled by the worker to prevent energy flow during service
Tagout: Placing a tag on the lockout device to communicate the lockout status and warn others not to reenergize the equipment
How does it work?
Prevents activation: Ensures equipment cannot be turned on or release energy during service.
Disconnect power: All power sources are disconnected and locked in the off position.
Personal locks: Each worker uses their own lock and key to control the energy source.
Warning tags: Tags are placed on locks to warn others and identify the responsible person.
Verification: Before starting work, each worker verifies the energy source is locked out.
Designated personnel: In some facilities, only designated people can lock out power sources or use group lockout processes.
Key steps of lockout/tagout
Identify equipment and energy sources: Determine all energy sources (electrical, mechanical, hydraulic, pneumatic, etc.) associated with the equipment.
Notify affected employees: Inform all employees who work on or near the equipment about the shutdown and LOTO procedures.
Shut down equipment: Turn off the equipment using the normal stopping procedure.
Isolate energy sources: Disconnect and isolate all energy sources to ensure the equipment cannot be started.
Apply lockout/tagout devices: Attach locks and tags to each energy-isolating device to prevent accidental re‑energization.
Release stored energy: Safely release or restrain any stored energy (e.g., capacitors, springs, hydraulic pressure).
Verify isolation: Test the equipment to ensure it is properly locked out and cannot be started.
Perform maintenance or servicing: Complete the required work on the equipment.
Remove lockout/tagout devices: After the work is completed, remove all tools and notify employees that the locks and tags will be removed.
Restart equipment: Ensure all safety devices are restored and then restart the equipment following standard procedures.
