Lockout/Tagout Steps: The 6-Step LOTO Procedure Explained

Lockout/tagout (LOTO) is a set of procedures that keeps machines and equipment safely shut down while someone services or maintains them. A lockout device (usually a padlock) physically holds an energy-isolating device, such as a breaker or valve, in the safe position. A tagout device is a prominent warning tag attached to the isolating device that says the equipment must not be operated.

Hazardous energy is not only electrical. It includes mechanical, hydraulic, pneumatic, chemical, thermal and gravitational energy, plus stored energy in springs, capacitors, flywheels and raised parts. OSHA requires employers to have an energy control program with written procedures, training and periodic inspections. Locks are the default: tags alone may be used only when an isolating device cannot accept a lock, or when the employer can show tagout provides full employee protection.

1. Prepare for shutdown. The authorized employee identifies every type and amount of energy that powers the machine, the hazards of that energy, and how to control it. The machine’s written procedure is the guide.
2. Shut down the machine. Turn it off using the normal stopping procedure (stop button, switch or valve) so no one is endangered by an abrupt stop. Notify affected employees first.
3. Isolate the machine. Operate every energy-isolating device (circuit breakers, disconnect switches, valves, blocks) so the machine is cut off from all energy sources. Push buttons and selector switches are not energy-isolating devices.
4. Apply lockout or tagout devices. Each authorized employee attaches their own lock and tag so the isolating devices are held in the “safe” or “off” position.
5. Release or restrain stored energy. Relieve, disconnect, restrain or otherwise make safe any stored or residual energy: bleed pressure, discharge capacitors, block raised parts, let hot parts cool. If energy could build up again, keep checking.
6. Verify isolation. Before starting work, confirm the machine is actually de-energized, for example by trying the normal start controls (then returning them to off) and testing with a meter where electrical energy is involved.

Only after step 6 is it safe to begin servicing or maintenance.

Removing a lockout has its own steps under 1910.147(e):

1. Inspect the machine. Remove nonessential items such as tools and parts, and make sure all components are intact.
2. Check that everyone is clear. All employees must be safely positioned or removed from the area.
3. Notify affected employees that the locks and tags have been removed before the machine is restarted.
4. Remove the devices. Each lock or tag is removed by the employee who applied it.

If the employee who applied the lock is not available, the employer may remove it only under a specific written procedure: verify the employee is not at the facility, make every reasonable effort to contact them, and make sure they know the lock was removed before they return to work.

• Group lockout: when a crew services equipment, each authorized employee must have personal control of the work through their own lock, often on a group lockbox, with one authorized employee in overall charge.
• Shift or personnel changes: specific procedures must ensure continuity of protection, such as an orderly transfer of locks between off-going and incoming employees.
• Outside contractors: the on-site employer and the contractor must inform each other of their energy control procedures.
• Cord-and-plug equipment: the standard does not apply when the hazard is fully controlled by unplugging and the plug stays under the exclusive control of the person doing the work.
• Minor servicing: routine, repetitive tasks during normal production may be exempt only if other measures give effective protection.

Construction, agriculture and maritime work are outside 1910.147, though similar rules apply elsewhere, such as the electrical rules in 1910.333 and 1926.417.

OSHA sets three levels of training under 1910.147(c)(7):

Where tags are used, workers must also learn their limits: a tag is only a warning and gives none of the physical protection of a lock. Retraining is required when job assignments, machines or procedures change, and whenever an inspection shows gaps in knowledge. The employer must certify that training was done, with each employee’s name and the dates of training.

Each energy control procedure must also be inspected at least once a year by an authorized employee other than the ones using it, and the employer must certify that inspection.

OSHA does not approve, certify or accredit online training providers. An online LOTO course covers the principles and the standard; your employer must add training on your machines and written procedures and show you how its locks, tags and devices are used. With Gama Safety you pass the exam with 80% or better (unlimited free retakes) and download your certificate and printable wallet card right away.