Step-by-Step Guide to Effective Lockout Tagout Procedures

by | Aug 15, 2025 | Safety Signs

Lockout Tagout (LOTO) procedures are essential for keeping workers safe when servicing or maintaining equipment. They prevent dangerous machinery from starting up unexpectedly and protect against the sudden release of hazardous energy. When done right, LOTO not only saves lives but also ensures compliance with OSHA standards. 

Complete Guide to Effective Lockout Tagout Procedures

If you want to make sure your workplace follows lockout tagout procedures effectively, here’s a simple step-by-step guide.

1. Identify All Energy Sources

The first step in an effective LOTO process is identifying every possible energy source connected to the equipment. This includes electrical, hydraulic, pneumatic, mechanical, chemical, and thermal energy.

Many machines have more than one energy source, so it’s important to review the manufacturer’s manual or the company’s equipment log. By knowing exactly where and how energy is supplied, you can make sure no hazards are overlooked during shutdown.

2. Notify All Affected Employees

Before shutting down any equipment, notify every worker in the area. Communication is key here—people need to know why the machine is being locked out, how long it will be offline, and who is authorized to remove the lock or tag.

This step prevents confusion and ensures that no one tries to operate the equipment while it’s being serviced. Clear communication also helps build a safety-first culture in the workplace.

3. Shut Down the Equipment

Once everyone is informed, proceed to shut down the machinery according to the manufacturer’s instructions. This step should be done in a controlled, deliberate manner to avoid sudden movements or energy release.

Use proper shutdown sequences, such as turning off switches, closing valves, and stopping moving parts completely. Never skip this step or rush through it—safe shutdown is the foundation of effective LOTO.

4. Isolate and Lock Out the Energy Sources

After shutdown, isolate each energy source by disconnecting or blocking it. Then, apply the lockout device to physically prevent reactivation.

  • Lockout: Use a padlock or other securing device.
  • Tagout: Attach a tag clearly stating that the machine is under maintenance and must not be operated.

In many workplaces, both locking and tagging are used together for maximum safety. Remember—only authorized employees should apply locks and tags, and each person should have their own unique lock key.

5. Release Stored or Residual Energy

Even after a machine is shut down and locked out, there may still be stored energy in springs, capacitors, hydraulic lines, or compressed air systems. Release this energy by bleeding, draining, discharging, or blocking it as required.

If stored energy can’t be completely released, make sure it’s secured or restrained so it can’t cause harm during servicing.

6. Verify Isolation Before Work Begins

The final—and often most overlooked—step is verification. Test the controls to ensure that the machine won’t start and that no energy is present. This may involve pressing start buttons, testing gauges, or inspecting pressure indicators.

Conclusion: Complete Guide to Effective Lockout Tagout Procedures

Following a Lockout Tagout procedure isn’t just about following rules—it’s about protecting lives. By identifying energy sources, communicating clearly, shutting down safely, locking and tagging properly, releasing stored energy, and verifying isolation, you create a workplace where accidents are far less likely to happen. Remember, the details matter—because in safety, cutting corners is never an option.