OSHA Lockout/Tagout Inspection Checklist

What lockout/tagout is and why it matters

Lockout/tagout is the practice of isolating hazardous energy sources before anyone cleans, services, adjusts, or sets up machinery. Equipment that can move, or that stores energy in mechanical, hydraulic, or pneumatic form, can cause serious injury if it starts or releases energy unexpectedly. This checklist supports a systematic OSHA Lockout/Tagout inspection of equipment and machinery, control valve handles, and stored energy systems so that energy-isolating devices, locks, tags, and procedures are in place and used consistently.

What a strong lockout/tagout program covers

A strong program starts with the equipment itself. All machinery or equipment capable of movement should be de-energized or disconnected and locked out during cleaning, servicing, adjusting, or setting up operations when necessary. Where equipment energy disconnect means do not also disconnect the electrical control circuit, supplementary lockout provisions should be established and implemented. Electrical cabinets should be clearly identified and labeled, and adequate means should be provided to disconnect and lock out the control circuit independently. The practice of locking out control circuits in lieu of locking out main power disconnects should be strictly prohibited and enforced. Control valve handles should have a positive locking means for secure lockout, and the procedure should mandate that all stored energy be released or safely blocked before equipment is locked out for repairs.

Personal locks, tags, and verification

Each authorized employee should be provided with a personal safety padlock equipped with an individual, unique key, and employees should maintain exclusive personal control of their keys whenever their safety locks are in use. Only the employee exposed to the hazard should be permitted to place or remove their personal safety lock. After positively ensuring that no personnel are exposed, employees should verify the effectiveness of the lockout by attempting a start-up, then immediately press the stop button on the control circuit. Provisions should also be in place to identify any or all employees working on locked-out equipment through their individual locks or accompanying tags, and an adequate supply of accident prevention signs, tags, and safety padlocks should be maintained for any reasonably foreseeable repair emergency.

Special situations

Some tasks require additional precautions. When machine operations, setup, or dimensions require the operator to leave the control station to install tools or perform other operations, and if that part of the machine could move upon accidental activation, the machine element should be separately locked or blocked. In situations where equipment or lines cannot be shut down, locked out, and tagged out, an established safe work procedure should be rigorously developed and followed.

Frequently Asked Questions

Lockout/tagout is a formal procedure used to prevent machinery or equipment from releasing hazardous energy while it is being cleaned, serviced, adjusted, or set up. It covers electrical, mechanical, hydraulic, pneumatic, and other stored energy sources. Before work begins, the equipment must be de-energized or disconnected and locked out, and all stored energy must be released or safely blocked.

Lockout/tagout controls hazardous energy so that equipment cannot start or move unexpectedly while people are working on or near it. This protects employees from injuries during cleaning, servicing, adjusting, and setup operations. A systematic inspection confirms that energy-isolating devices, locks, tags, and procedures are in place and used consistently, and helps you identify and correct gaps before an incident occurs.

The inspection checks whether all machinery capable of movement is de-energized or disconnected and locked out during cleaning, servicing, adjusting, or setup. It verifies that electrical cabinets are clearly identified and labeled, that control circuits can be disconnected and locked out independently, and that locking out control circuits instead of main power disconnects is prohibited. It also reviews stored energy release or blocking, positive locking means on control valve handles, personal safety padlocks with unique keys, exclusive employee control of keys, and verification of lockout effectiveness before work proceeds.

You conduct the inspection systematically across the equipment and machinery in scope. You review the lockout/tagout procedure, confirm that energy-isolating devices and control circuits can be locked out, and check that stored energy such as mechanical, hydraulic, and pneumatic energy is released or safely blocked. You verify that authorized employees have personal safety padlocks with individual keys, that only the exposed employee places or removes their own lock, and that lockout effectiveness is verified by attempting a start-up after ensuring no personnel are exposed.

You record the audit inspection details, including the date conducted, who prepared it, the location, and the primary department inspected. You document findings and recommendations, the total number of lockout/tagout devices inspected, and the overall program compliance rating. You also capture a signature and the inspection start and end times to complete the record.

Written by

Arne Reis

Founder

Process optimizer with 25 years of expertise, focused on operational excellence in quality, maintenance, EHS, and commissioning. Emphasizes innovative solutions and top-quality standards.

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