What is Lockout Tagout?

Lockout Tagout (LOTO) is a safety procedure designed to keep workers safe from sudden releases of hazardous energy during equipment maintenance or repairs. It involves placing a lock—like a padlock—on energy control points to physically prevent the machine from being turned on. A tag is also added to warn others not to use the equipment.

Without proper LOTO practices in place, machines could unexpectedly start up or release stored energy, putting workers at serious risk of injury—or worse. It’s a critical step in making maintenance safe.

What Are the 7 Steps of Lockout Tagout Procedure?

The Lockout Tagout (LOTO) procedure is a step-by-step safety process used in many industries to prevent machines from accidentally turning on during maintenance or repair. It protects workers from unexpected energy releases. Here’s a breakdown of the 7 key steps involved:

1. Prepare for Shutdown
The authorized worker identifies the equipment to be serviced, understands how it operates, and determines which energy sources (like electricity, hydraulics, or steam) need to be controlled. Any potential hazards must be recognized during this stage.

2. Notify Affected Employees
Before anything is shut down, anyone working near or with the equipment must be informed. This includes details about what’s being locked out, why, for how long, and who is performing the work.

3. Power Down Equipment
Follow the standard shutdown procedure for the machine. Turn off controls, switches, or buttons, and ensure all moving parts stop completely.

4. Isolate the Energy Source
Disconnect the equipment from its power source. This could mean flipping a breaker, closing a valve, or unplugging a machine—whatever ensures there’s no energy feeding into it.

5. Release Stored Energy
Even after power is cut, machines can hold dangerous energy (like pressure or heat). This step involves safely draining, bleeding off, or blocking any leftover energy so it can’t cause harm.

6. Apply Lockout/Tagout Devices
Place locks on all energy-isolating points to prevent re-energization. Attach a tag with the worker’s name and details about the lockout for visibility and accountability.

7. Verify Isolation
Before any work begins, double-check that the machine is fully de-energized. Try turning it on using the control panel—if nothing happens, the lockout is working, and it’s safe to proceed.

What Is the Difference Between Lock Out and Tag Out?

Lockout and tagout are both safety measures, but they work differently. Lockout involves using a physical lock—like a padlock—to block a machine from being turned on. It completely stops access to the energy source.

Tagout, on the other hand, involves placing a warning tag on the equipment to alert others that it’s under maintenance and shouldn’t be operated. While tagout doesn’t physically block the machine, it acts as a clear visual warning.

In short: Lockout provides physical control, while tagout offers a visual alert. Lockout is the stronger safeguard, and tagout adds an extra layer of safety.

Who Is Involved in a Lockout Tagout?

Several key roles are involved in a Lockout Tagout (LOTO) procedure. Safety supervisors are responsible for overseeing the entire process and ensuring proper protocols are followed. Authorized employees are trained personnel who physically apply the locks and tags before performing maintenance or repairs.

Then there are affected employees—these are workers who operate the machinery or work nearby. While they don’t apply the lockout devices, they must be informed and follow safety guidelines to avoid accidental startups.

Everyone involved plays a critical role in making sure the equipment stays safely shut down until it’s ready to be used again.

What to Do If an Employee is Not Available to Remove the Lock?

If the person who applied the lock isn’t available, the safety supervisor may remove it—but only under strict conditions. They must first verify that the employee is not on-site, confirm they’ve been properly trained, and follow the official lock removal procedure.

This ensures the Lockout Tagout (LOTO) system stays safe and controlled, and that no one accidentally restarts equipment before it’s truly safe to do so.

What Types of Hazards Does Lockout Tagout Protect Against?

Lockout Tagout (LOTO) protects workers from various hazardous energy sources, including electrical, mechanical, hydraulic, pneumatic, chemical, and thermal energy.

Without proper precautions, these energies can cause serious injuries such as electric shocks, crushing incidents, sudden pressure releases, chemical exposure, or burns. A well-implemented LOTO program ensures that these risks are safely controlled by isolating the energy sources before any maintenance or servicing work begins.