Every year thousands of workers get killed or injured while performing repairs or maintenance on industrial equipment or machinery. These accidents are caused by the unexpected energization or start-up of machines or equipment or by the uncontrolled release of energy. Many of these accidents can be prevented by implementing proper LOCKOUT TAGOUT.

Lockout Tagout,  also known as LOTO or LOTOTO, is a safety procedure used in industries and workplaces to control hazardous energy sources during servicing, maintenance, and repair activities. It involves the isolation of energy sources and the application of lockout and tagout devices to ensure the prevention of accidental startup or release of stored energy.

The purpose of lockout tagout is to protect workers from hazardous energy sources, such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy sources, which can cause injury or fatalities if not properly controlled. The procedure ensures that machinery or equipment is safely de-energized and cannot be energized until maintenance or servicing tasks are completed.

The term “Lockout Tagout” is directly associated with OSHA Standard 29 CFR Part 1910.147. This standard, issued by the Occupational Safety and Health Administration (OSHA) in the United States, establishes the requirements for implementing and enforcing lockout tagout procedures in various industries.

The history of LOTO can be traced back to several significant events that highlighted the need for standardized safety practices. This article delves into the evolution of LOTO, its inception, and its importance in ensuring worker safety.

1. Lockout: Lockout involves the physical placement of a lock on an energy-isolating device, such as an electrical switch or valve, to prevent the release of hazardous energy. The lock serves as a physical barrier that keeps the machinery or equipment from being energized. Only the authorized person who applied the lock has the key or combination to remove it.
2. Tagout: Tagout involves the use of a prominent warning tag or sign that is attached to an energy-isolating device to indicate that it must not be operated or energized. The tagout device provides information about the person who applied it and the reason for its application. It serves as a visual warning to inform workers that maintenance or servicing is taking place and that the equipment should not be used.
3. Energy-Isolating Device:  An energy-isolating device is a mechanical device, such as a switch, circuit breaker, valve, or disconnect, that controls the flow of energy to a particular piece of equipment or machinery. During lockout tagout, these devices are physically turned off, closed, or otherwise isolated to prevent the release of hazardous energy.
4. Authorized Employees: Authorized employees are trained individuals who are responsible for implementing lockout tagout procedures. They have the knowledge and skills to properly perform the procedure, including the application and removal of lockout tagout devices. Click here to learn more.
5. Affected Employees: Affected employees are workers who may be exposed to the equipment or machinery undergoing lockout tagout procedures. They are informed of the ongoing maintenance or servicing activities and are instructed not to operate or energize the equipment. Click here to learn more.

1. Hazardous Energy: Any type of energy source that can cause harm to workers, including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, or other energy sources.
2. Lockout: The placement of a lockout device on an energy-isolating device, usually an electrical switch or valve, to prevent the release of hazardous energy. The lockout device physically prevents the machinery or equipment from being energized.
3. Tagout: The use of a warning tag attached to an energy-isolating device to indicate that it must not be operated or energized. A Tagout device is usually a prominent warning tag or sign that provides information about the person who applied it and the reason for its application.

1. Awareness: Affected employees are informed about the ongoing lockout tagout procedures. They are made aware that maintenance or servicing activities are being carried out on specific machinery or equipment and that it is temporarily out of operation.
2. Restriction: Affected employees are instructed not to operate or energize the equipment during the lockout tagout process. They must understand the potential hazards associated with the machinery or equipment and comply with the safety instructions given by authorized employees.
3. Communication: Affected employees communicate with authorized employees to coordinate work activities effectively. They may need to provide information about the equipment or machinery, its status, or any specific requirements or concerns they have regarding the maintenance or servicing tasks.
4. Support: Affected employees support the implementation of lockout tagout procedures by respecting the application of lockout tagout devices. They should report any observed deviations or concerns related to the lockout tagout process to authorized employees.
5. Safety Observance: Affected employees should be vigilant about their own safety and the safety of others in the area. They should avoid any attempts to bypass or tamper with lockout tagout devices and report any potential risks or hazards they notice during the maintenance or servicing process.

1. Training: Authorized employees receive thorough training on the purpose, procedures, and requirements of lockout tagout. They are educated on recognizing hazardous energy sources, understanding the steps involved in the lockout tagout process, and knowing how to properly apply and remove lockout tagout devices.
2. Knowledge and Expertise: Authorized employees have a comprehensive understanding of the machinery or equipment they are working on, including its energy sources, potential hazards, and specific lockout tagout requirements. They possess the expertise to identify and control energy sources effectively.
3. Application of Lockout Tagout Devices: Authorized employees are responsible for physically applying lockout and tagout devices to energy-isolating devices. They have the necessary tools, equipment, and access to the appropriate lockout tagout devices required for the task.
4. Communication: Authorized employees effectively communicate with affected employees, informing them about the lockout tagout process and the reasons behind it. They ensure that affected employees understand the importance of not operating or energizing the equipment during maintenance or servicing.
5. Responsibility and Authority: Authorized employees have the authority to implement and enforce lockout tagout procedures. They are entrusted with the responsibility of protecting themselves and their colleagues by ensuring that hazardous energy sources are adequately controlled.

1. Identify the Equipment: Determine the specific equipment or machinery that will be worked on and understand its energy sources. This includes electrical, mechanical, hydraulic, pneumatic, chemical, or other energy sources..
2. Employee Notification: Notify affected employees about the upcoming maintenance or servicing activities. Ensure clear communication about the nature of the work, potential hazards, and the need for lockout tagout procedures.
3. Lockout Tagout Devices: Gather the necessary lockout tagout devices, including lockout hasps, padlocks, tags, and tagout devices. Ensure they are in good working condition.

1. Affected Employee Notification: Inform affected employees that the equipment will be shut down for maintenance or servicing. Clearly communicate the time frame and any necessary precautions
2. Proper Equipment Shutdown: Follow the appropriate procedures to safely shut down the equipment. This may involve following the manufacturer’s instructions, using control switches, or shutting off energy sources.

1. Energy-Isolating Devices: Identify and locate all energy-isolating devices that control the equipment’s energy sources, such as electrical switches or valves.
2. Lockout Device Application: Apply lockout devices to each energyisolating device. These devices physically prevent the operation or energization of the equipment. Ensure that lockout devices are securely fastened in place.

1. Verify Isolation: Before proceeding, confirm that all energy sources have been effectively isolated. Follow specific procedures to safely dissipate or release any stored energy. This may involve bleeding pressure, draining fluids, or discharging capacitors.

1. Lockout Device Attachment: Attach lockout devices to each energy-isolating device. This ensures that the devices cannot be operated or energized. The lockout devices should be securely attached and capable of withstanding external forces.
2. Tagout Device Application: Use tags or tagout devices that clearly indicate the reason for the lockout, such as “Do Not Operate” or “Under Maintenance.” Tags provide a visual warning and should contain relevant information like the name of the authorized person and the expected completion time.

1. Task Execution: Once the lockout tagout procedures are in place and verified, perform the necessary maintenance or servicing tasks according to established procedures and safety guidelines. This may include repairs, adjustments, cleaning, or inspections.

1. Work Area Cleanup: Once the maintenance or servicing is completed, ensure that all tools, equipment, and personnel are removed from the work area.
2. Lockout Tagout Device Removal: Remove lockout tagout devices only when it is safe to re-energize the equipment. This should only be done by the authorized employee who applied the devices.
3. Employee Notification: Notify affected employees that the lockout tagout has been completed and that the equipment is ready for use. Provide any necessary safety instructions or precautions.

1. Worker Safety: The primary benefit of using lockout tagout is the protection of workers from the unexpected release of hazardous energy. By isolating and de-energizing machinery and equipment, lockout tagout prevents workers from being exposed to potentially dangerous energy sources, reducing the risk of injuries and fatalities.
2. Prevention of Accidental Startup: Lockout tagout procedures ensure that machinery or equipment cannot be unintentionally started or energized during maintenance, repair, or servicing. This eliminates the risk of accidental activation, which can lead to severe injuries or fatalities for workers who are in close proximity to the equipment.
3. Hazard Mitigation: Lockout tagout helps mitigate the risk of workplace hazards associated with the release of stored energy. Whether it is electrical, mechanical, hydraulic, pneumatic, chemical, or thermal energy, proper lockout tagout procedures minimize the potential for accidents and injuries caused by these energy sources.
4. Compliance with Regulations: Implementing lockout tagout procedures ensures compliance with regulations such as OSHA Standard 29 CFR Part 1910.147. Meeting regulatory requirements not only promotes a safe work environment but also helps employers avoid penalties, fines, and legal issues resulting from non-compliance.
5. Increased Safety Awareness: Lockout tagout procedures raise safety awareness among employees. By implementing and following LOTO protocols, workers become more cognizant of the potential hazards associated with machinery and equipment. This heightened awareness can extend to other safety practices, fostering a safety-conscious culture throughout the workplace.
6. Enhanced Communication: Lockout tagout procedures require effective communication between authorized and affected employees. This communication promotes teamwork and ensures that everyone involved in the maintenance or servicing tasks understand the status of equipment and the importance of adhering to safety protocols.
7. Cost Savings: While the primary goal of lockout tagout is to protect worker safety, it also leads to cost savings for employers. By preventing accidents and injuries, lockout about reduces medical expenses, workers’ compensation claims, and potential legal costs associated with workplace incidents. Additionally, minimizing downtime due to accidents and equipment damage improves productivity and operational efficiency. Employers can prevent workplace accidents and mitigate the associated costs, which can be substantial.
   1. Reduction in Medical Expenses: Workplace accidents resulting from the failure to implement lockout tagout can lead to serious injuries that require medical treatment. This includes costs associated with emergency medical care, hospitalization, surgeries, medications, and rehabilitation. By preventing accidents through lockout tagout, employers can avoid these medical expenses.
   2. Decreased Workers’ Compensation Claims: Accidents resulting from the lack of lockout tagout can lead to workers’ compensation claims, which can be financially burdensome for employers. By implementing effective lockout tagout procedures, employers can reduce the frequency and severity of accidents, resulting in fewer workers’ compensation claims and lower associated costs.
   3. Productivity and Downtime Savings: Accidents caused by the failure to properly lockout tagout machinery or equipment can result in work disruptions and downtime. The time taken for medical treatment, accident investigations, and repairs can lead to decreased productivity and operational delays. By preventing accidents through lockout tagout, employers can minimize downtime and maximize productivity.
   4. Legal and Regulatory Compliance: Compliance with lockout tagout regulations, such as OSHA Standard 29 CFR Part 1910.147, helps employers avoid potential legal penalties and fines. Noncompliance can result in costly litigation, regulatory investigations, and reputational damage. Implementing effective lockout tagout practices ensures compliance and mitigates the financial risks associated with non-compliance

1. Communication: The authorized person in charge of the group lockout process communicates the lockout procedures and the scope of work to all workers involved. This ensures that everyone understands their responsibilities and the importance of adhering to the established procedures.
2. Equipment Identification: The equipment or machinery that requires maintenance or repair is identified, and all energy isolation points associated with it are determined.
3. Energy Isolation: The authorized person leads the group in isolating and securing the energy sources according to the established lockout procedures. This may involve shutting off power, closing valves, releasing pressure, or other necessary steps to render the equipment safe.
4. Group Lock Application: Each worker participating in the group lockout applies their individual lock to the energy isolation points. This ensures that no single worker can re-energize the equipment without the knowledge and consent of the entire group.
5. Verification: Once the locks are applied, the authorized person verifies that all energy sources are effectively isolated by attempting to start or energize the equipment. This step ensures that the locks have been correctly applied and that the equipment cannot be inadvertently powered on.
6. Tagout: In addition to the individual locks, a group lockout tag may also be attached to the energy isolation points. The group lockout tag provides additional information about the work being performed, the workers involved, and any specific precautions or requirements.
7. Work Performed: With the equipment properly isolated and locked out, the maintenance or repair work can be carried out safely. Workers should follow the established procedures and best practices for working on or near locked-out equipment.
8. Completion and Lock Removal: Once the maintenance or repair work is completed, the authorized person ensures that all workers are clear of the equipment and the work area is safe. Only the authorized person can remove the individual locks after confirming that it is safe to do so.

1. Inadequate Training: Insufficient training of employees on lockout tagout procedures can result in errors or ignorance of the proper steps to take. This may lead to failure in identifying energy sources, applying lockout devices, or following the established protocols.
2. Miscommunication: Poor communication among workers involved in maintenance activities can lead to misunderstanding or ignorance of ongoing lockout tagout procedures. Without clear communication channels, employees may unintentionally energize equipment or interfere with the isolation measures, risking accidents.
3. Failure to Follow Procedures: Neglecting to strictly adhere to lockout tagout procedures can have disastrous consequences. Employees may bypass lockout devices, remove tags without authorization, or attempt maintenance activities without proper isolation, exposing themselves and others to hazardous energy sources.
4. Lack of Equipment Inspections: Failure to regularly inspect lockout tagout devices and equipment can lead to malfunction or damage. If devices are defective or unreliable, they may not effectively prevent the accidental release of hazardous energy.

1. Equipment-related Injuries: Accidental energization of equipment can result in severe injuries, such as electrocution, burns, amputations, or crushing injuries. Without proper lockout tagout measures in place, workers can be exposed to uncontrolled energy sources, leading to life-threatening incidents.
2. Worker Fatality: In extreme cases, negligence in lockout tagout can result in fatal accidents. The failure to properly isolate energy sources can lead to unexpected equipment startup or the release of stored energy, causing fatal injuries to workers involved in maintenance activities.
3. Legal and Financial Consequences: Organizations that neglect lockout tagout procedures may face legal repercussions, including fines and penalties for non-compliance with safety regulations. Additionally, legal settlements and compensation claims resulting from accidents can lead to significant financial losses for the organization.

1. Providing Comprehensive Training: Ensuring that all employees involved in maintenance activities receive thorough training on lockout tagout procedures, including recognizing hazardous energy sources, understanding the purpose and use of lockout tagout devices, and following established protocols.
2. Establishing Clear Communication: Implementing effective communication channels to inform employees about ongoing lockout tagout activities, sharing updates, and coordinating tasks to avoid conflicts or misunderstandings.
3. Enforcing Compliance: Regularly monitoring and enforcing compliance with lockout tagout procedures to ensure that all employees strictly follow the established protocols and use appropriate lockout tagout devices.
4. Conducting Equipment Inspections: Regularly inspecting and maintaining lockout tagout devices and equipment to ensure they are in proper working condition, reliable, and capable of effectively isolating energy sources.