Lockout Tagout Procedures & Safety

Last updated November 12, 2024
Lockout Tagout is a specific procedure that protects personnel working on machinery and equipment. It should be developed and documented by employers for any machine that could endanger workers if it were turned on during service or maintenance.
Table of Contents
Create Your Procedure
Train, Practice & Put It to Work
Conditions & Exceptions
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Create Your Procedure

OSHA sets minimum requirements for lockout tagout (also known as controlling hazardous energy, energy-control procedures or LOTO). Adhere to these standards and exceed them where possible to protect personnel.
Take the first steps toward protecting the people who depend on you. Identify the equipment and machinery that require Lockout Tagout procedures, and categorize those devices by their controls.
Take the first steps toward protecting the people who depend on you. Identify the equipment and machinery that require Lockout Tagout procedures, and categorize those devices by their controls.
Equipment needs Lockout Tagout procedure if:
- It has or comes with a Lockout Tagout device installed
- It can be activated without warning during maintenance
The same Lockout Tagout procedure may be used if equipment uses the same controls or LOTO interface. If various conditions, interfaces, controls, energy sources or power connections exist, separate procedures must be developed.
Write Your Procedure
Create a dedicated process for Lockout Tagout to control hazardous energy. Document it in detail, including purpose, scope, rules and authorizations. Your procedure should also include the specific methods your employees will use. Your procedure should:
- Establish a step-by-step program to control energy
- Explain exactly what employees need to know before maintenance
- Completely separate machines from their energy sources
- Consider and eliminate any stored or built-up energy
- Render machines inoperable throughout maintenance procedures
- Include proper and safe placement and transfer of Lockout Tagout devices
- Include testing requirements to ensure equipment is deactivated
- Be specific to each piece of equipment or lockout interface
Pro Tip:
OSHA allows Tagout strategies on machinery with Lockout devices as long as it provides the same level of protection as Lockout
Train, Practice & Put It to Work

With your program written and ready, train your staff. All employees should be aware of Lockout Tagout procedures. Your service or maintenance staff should be intimately familiar with the process. Be thorough. Any accidental discharge is a significant threat to safety.
Practice your program and evaluate it at regular intervals. At minimum, practice and reevaluation should occur annually or when new equipment is introduced. Biyearly or even quarterly reviews could be ideal depending on your industry.
Put Your Plan to Work
Your procedure is written, practiced and ready to protect your personnel. It complies with OSHA’s Lockout Tagout requirements. Put it to work.
- Shutdown the machine completely
- Disconnect power and separate the machine from any and all energy sources
- Attach all Lockout or Tagout devices
- Discharge or restrain any potential energy retained in the machinery
- Verify the machine is completely inoperable—twice
- Maintain and service the machinery
Reactivation
Maintenance is finished. Service is done. It’s time to bring things back online. Take caution. Every employee must respect and follow the procedures you create. Failure to do so can result in serious injuries and deaths. The only employee who should remove Lockout Tagout devices is the employee who applied them.
Before disconnecting Lockout Tagout devices:
- Thoroughly inspect the machine and its components
- Check for foreign objects, including tools and PPE
- Ensure all personnel are at a safe distance
Once Lockout Tagout devices are removed, alert all personnel and everyone in the area: The machine is now operational. The job is done. Production is ready to resume.
Conditions & Exceptions

If machinery or equipment can be turned on or somehow activated without warning, it needs Lockout Tagout procedures. This includes devices that use and store all types of energy, including:
- Electrical
- Hydraulic
- Pneumatic
- Thermal
- Mechanical
Exceptions
In general, if someone can disconnect equipment from and keep control of its power source, Lockout Tagout standards do not apply. Most power tools are excluded for example. However, this is only true if electrical energy is the only energy threat. If residual energy (like lingering charge, steam or mechanical energy) can be present, Lockout Tagout standards apply.
Standards also do not apply to minor changes and routine services as long as the work is repetitive and essential. Other protection against hazardous energy are required when applying this exception.
Industry Exceptions
Construction, maritime, agriculture and oil and gas drilling industries, as well as work with conductors and premise wiring, are not covered by OSHA’s Lockout Tagout standards. These industries and jobs are covered by separate OSHA regulations in 29 CFR 1910.333 and 1910.269 and various other standards for the control of hazardous energy.
Secondary Reactivation
Situations where different personnel deactivate equipment should be rare. In these uncommon cases, OSHA guidelines allow secondary personnel to reactivate machinery. To do so, these employees must be trained, operate under your direction as their employer and strictly follow procedures.
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