What Is Lockout Tagout (LOTO)? OSHA Steps & Checklist

Workplace Safety · 16 min read · Updated August 2026

What is Lockout Tagout? (LOTO Safety)

In the world of industrial and workplace safety, “Lockout Tagout” (LOTO) stands as a crucial procedure that safeguards workers from potentially life-threatening accidents caused by the unexpected release of hazardous energy sources. This comprehensive safety protocol serves as a vital protective measure, aiming to prevent machinery or equipment from powering on or moving during maintenance, repairs, or servicing.

Lockout_tagout Procedures

Key Takeaways

  • LOTO means lockout/tagout — isolating a machine’s energy sources and locking them so the equipment cannot start while someone is servicing it.
  • Lockout is physical protection; tagout is a warning. Tagout alone is only acceptable when an isolation device cannot accept a lock.
  • Every procedure must account for six energy types: electrical, mechanical, hydraulic, pneumatic, chemical, and thermal — including stored energy.
  • OSHA 29 CFR 1910.147 requires paperwork, not just locks: written machine-specific procedures, trained and documented authorized employees, and a certified inspection of every procedure at least annually.
  • Documentation is where most programs fail — which is why LOTO records increasingly live in a CMMS alongside the work orders that trigger them.

What is Lockout Tagout?

Understanding the significance of Lockout Tagout is essential for employers and employees alike, as it not only preserves lives but also supports compliance with regulatory standards to maintain a secure working environment.

Lockout Tagout (LOTO) is a safety procedure used in industrial settings to protect workers from hazardous energy sources while performing maintenance, repairs, or servicing on machinery or equipment. The primary purpose of Lockout Tagout is to prevent unexpected startup or release of stored energy, such as electrical, mechanical, hydraulic, pneumatic, chemical, or thermal energy, which could cause injury or even death to workers.

During a Lockout Tagout procedure, authorized personnel apply locks or tags to energy isolation points of the machinery or equipment. Locks physically prevent the machinery from being energized, while tags provide a visual warning that the equipment is under maintenance and must not be operated.

The process involves several steps, including identifying energy sources, isolating the equipment, applying locks and tags, releasing any residual energy, and verifying that the system is in a safe state before commencing work. Proper training and adherence to Lockout Tagout protocols are essential to ensure worker safety and prevent accidents in industrial environments.

For a short, plain-language definition, see our quick guide to what LOTO stands for.

Lockout vs. Tagout: What’s the Difference?

The two halves of LOTO do different jobs, and OSHA treats them differently. Lockout is the stronger control. Tagout alone is only acceptable when equipment cannot accept a lockout device.

  Lockout Tagout
What it does Physically prevents the equipment from being energized Provides a visual warning not to operate the equipment
Device used Padlock, hasp, valve or breaker lockout Durable warning tag attached at the isolation point
Level of protection Positive — the machine cannot start Warning only — relies on people obeying the tag
When it is used Whenever the energy isolation device can accept a lock Only where lockout is not possible, with additional safety measures

In practice, most programs use both together: the lock makes the equipment safe, and the tag tells everyone why it is locked, who locked it, and when work is expected to finish.

The Six Types of Hazardous Energy

A LOTO procedure only works if it accounts for every energy source feeding a machine. Missing one is how equipment that looks de-energized still injures someone.

Energy Type Common Sources How It Is Isolated
Electrical Motors, control panels, capacitors, batteries Open and lock the disconnect or breaker; discharge capacitors
Mechanical Flywheels, springs, suspended loads, rotating parts Block, chock, or pin moving parts; release spring tension
Hydraulic Presses, lifts, clamps, accumulators Close and lock valves; bleed off residual pressure
Pneumatic Air cylinders, actuators, compressed air lines Close and lock the supply valve; vent stored air
Chemical Process lines, tanks, reactive materials Close, lock, and blank or bleed the line; drain and purge
Thermal Steam lines, ovens, furnaces, hot surfaces Isolate the supply and allow the system to cool before work

The Importance of LOTO Safety

With the continuous advancement of industrial processes and the introduction of increasingly sophisticated machinery, specialized maintenance procedures became a necessity. However, this progress also brought about a higher risk of accidents, particularly concerning the maintenance of energized systems.

In the evolving landscape of industrial safety, incidents involving powerful machinery highlighted the critical need for a robust Lockout Tagout (LOTO) safety approach. Recognizing this imperative, the American National Standards Institute (ANSI) took the initiative in 1982 to provide guidance on LOTO practices, aimed at safeguarding workers from hazardous energy sources. Subsequently, in 1989, the Occupational Safety and Health Administration (OSHA) formalized LOTO guidelines into regulations, reinforcing the commitment to preserving lives and preventing injuries in the workplace.

OSHA Guidelines: Safeguarding Against Hazardous Energy

The comprehensive guidelines set forth by the Occupational Safety and Health Administration (OSHA) encompass a wide range of energy sources, including mechanical, electrical, hydraulic, pneumatic, chemical, and thermal elements. In the dynamic environment of manufacturing plants, maintenance activities often involve handling one or more of these energy sources.

The essence of Lockout Tagout (LOTO), as implied by its name, lies in two primary approaches that ensure employee safety during maintenance operations: lockout and tagout. Lockout physically restricts access to specific equipment, rendering it inoperable during maintenance. On the other hand, tagout employs visible warning signs to alert employees about potential hazards, serving as a crucial reminder of the need for caution. By adhering to these OSHA-prescribed measures, organizations can effectively protect their workforce from dangerous equipment and create a safer working environment.

Understanding the Mechanics of Lockout Tagout (LOTO)

To ensure workplace safety, OSHA has established clear guidelines in Title 29 of the Code of Federal Regulations (CFR) Part 1910.147, focusing on the proper maintenance and servicing of equipment that could potentially release hazardous energy. Companies must identify equipment falling under these regulations to not only avoid penalties but, more importantly, prioritize the well-being of their workers.

To maintain compliance with federal LOTO standards during maintenance activities, a robust documentation process is essential. By integrating LOTO procedures into the Computerized Maintenance Management System (CMMS), companies can enhance visibility and track the progress of riskier tasks, offering an added layer of safety and control. Emphasizing LOTO protocols supports adherence to regulations and fosters a safer working environment, safeguarding employees from potential harm.

Who Can Perform LOTO? Roles and Training Requirements

OSHA divides the workforce into three groups, and each needs a different level of training. Getting this wrong is one of the most common findings in a LOTO inspection, because employers often train the maintenance team and stop there.

Role Who They Are What Training Requires
Authorized employee The person who locks and tags the equipment and performs the service or maintenance Full training on hazardous energy recognition, the type and magnitude of energy in the workplace, and the methods for isolation and control
Affected employee Operators and others who use the equipment or work in the area where it is serviced Instruction in the purpose and use of the energy-control procedure, and the prohibition on restarting locked-out equipment
Other employee Anyone whose work is or may be in an area where energy-control procedures are used Instruction about the procedure and the prohibition on attempting to restart or re-energize locked-out equipment

Retraining is required when job assignments change, when machines or processes change, when a new hazard is introduced, or when an inspection reveals a deviation from the procedure. Employers must certify that training took place, including each employee’s name and the dates of training — which is why training records and LOTO records belong in the same system.

Safeguarding Workers: The Vital Steps of Lockout Tagout (LOTO)

Lockout Tagout (LOTO) is a critical safety procedure used to protect workers from hazardous energy sources during maintenance, repairs, or servicing of machinery or equipment. The steps involved in implementing LOTO may vary slightly depending on the specific equipment and workplace, but generally, the procedure involves the following key steps:

1. Preparation

Identify the machinery or equipment that requires servicing, maintenance, or repair. Notify all affected employees about the planned LOTO procedure and obtain the necessary permits.

2. Notify Affected Employees

Inform all employees who will be working on or near the equipment about the upcoming LOTO procedure. Clearly communicate the reason for the lockout and the expected duration of the procedure.

3. Shutdown

Turn off the equipment or machinery using the normal shutdown procedures. Follow the manufacturer’s guidelines and ensure that all controls are in the “off” position.

4. Isolation

Identify and isolate all energy sources that could potentially power the equipment. This may involve shutting off electrical switches, closing valves for hydraulic or pneumatic systems, blocking mechanical movements, and draining stored energy.

5. Application of Locks and Tags

Authorized personnel must apply lockout devices, such as padlocks, at each energy isolation point. Additionally, they should attach tags to indicate the reason for the lockout, the person responsible, and the expected completion time.

6. Release Stored Energy

After shutting down and isolating the equipment, verify that all sources of stored energy have dissipated. For example, release pressure from hydraulic or pneumatic systems and discharge capacitors in electrical systems.

7. Verification

Double-check that the equipment sits in a safe state and that no one can energize it. Then attempt to start the machinery using the normal controls to confirm it remains inoperative.

8. Perform the Task

Once you have locked out the equipment and confirmed it is safe, perform the required maintenance, repairs, or servicing.

9. Removal of Locks and Tags

When the task is complete, the employees who applied the locks and tags should be the ones to remove them. Before removal, ensure that all tools are clear, and everyone is safely positioned.

10. Reactivation

After the team finishes the service work and removes every lock and tag, follow the appropriate procedures to reactivate the machinery safely.

11. Communication

Finally, tell all employees that the lockout is over and the equipment is back in operation.

Each step in the LOTO process is crucial, and strict adherence to these procedures helps prevent accidents, injuries, and fatalities caused by the unexpected release of hazardous energy during maintenance activities. Proper training and understanding of the specific equipment and energy sources are essential for the effective implementation of Lockout Tagout.

Group Lockout, Shift Changes, and Outside Contractors

The standard procedure assumes one technician working on one machine. Real maintenance is rarely that tidy. Three situations need their own handling, and each is a common source of injury.

Group Lockout

When several people service the same equipment, each authorized employee must have their own lock on the isolation point — typically through a hasp that accepts multiple padlocks, or a group lockbox holding the isolation keys. As a result, no one depends on another person’s judgment about when it is safe to re-energize, because the machine cannot start until the last lock comes off.

Shift Changes

Protection must be continuous when work carries across a shift boundary. The outgoing authorized employee’s lock stays on until the incoming employee applies theirs, so the equipment never sits isolated but unlocked. A documented handoff records who is now responsible.

Outside Contractors

When an outside servicing company works on your equipment, the host employer and the contractor must inform each other of their respective energy-control procedures, and the host must make sure their own employees understand and comply with the contractor’s restrictions. Therefore, log contractor LOTO events exactly the way you log in-house work.

Removing Another Person’s Lock

Occasionally someone must remove a lock when its owner is unavailable. This requires a specific written procedure: verify the employee is not at the facility, make all reasonable efforts to contact them, and tell them their lock came off before they resume work. This should never be a routine or informal act.

Essential Tools for Lockout Tagout (LOTO) Safety

Lockout Tagout (LOTO) safety tools encompass a variety of equipment designed to effectively implement the procedure and protect workers from hazardous energy sources. Some common LOTO devices include:

Padlocks

Sturdy padlocks secure energy isolation devices — electrical switches, circuit breakers, valves, or pneumatic controls — in the off or closed position.

Lockout Hasps

A hasp holds several padlocks at once, so multiple authorized individuals can each lock out the same energy isolation point.

Lockout Tag

Tags warn everyone that the equipment carries a lockout and that no one may operate it. They typically carry essential information such as the reason for the lockout, the name of the authorized person, and the expected completion time.

Lockout Devices

Specialized lockout devices physically restrain and isolate specific energy isolation points, so no one can reenergize the equipment during maintenance.

Circuit Breaker Lockouts

These devices hold circuit breakers in the off position and prevent accidental or unauthorized reactivation of electrical circuits.

Valve Lockouts

Valve lockouts cover valve handles securely, so no one can open, close, or operate them during maintenance.

Plug Lockouts

Plug lockouts enclose electrical plugs and keep them out of power outlets.

Electrical Lockout Devices

These tools block electrical connectors, switches, or outlets to prevent electrical hazards.

Pneumatic Lockout Devices

These devices hold pneumatic controls closed and stop compressed air from escaping during maintenance.

In addition, tagout devices act as prominent warnings that visibly identify the equipment as potentially hazardous. These can take the form of signs or symbols that fasten securely to the equipment.

Maintenance teams also use non-physical tools, such as CMMS software, to improve LOTO efficiency. Tracking LOTO activities in maintenance management software supports accurate compliance with the standards and streamlines the overall safety procedures. As technology continues to evolve, integrating advanced software solutions further contributes to a safer work environment and reduces the risk of accidents related to hazardous energy sources.

The Most Common LOTO Violations

Top 5

The control of hazardous energy (1910.147) has appeared on OSHA’s Top 10 Most Frequently Cited Standards year after year, ranking among the five most-cited standards in recent fiscal years. Decades after the rule took effect, LOTO programs still fall short in predictable ways.

Inspectors tend to find the same handful of problems. None of them are about buying better locks.

  • No written, machine-specific procedure. A single generic policy covering every machine in the plant does not satisfy the standard where equipment has multiple energy sources.
  • Procedures that no longer match the equipment. Someone modifies a line, adds an energy source, and the document on the wall is now wrong.
  • No annual inspection, or no certification of it. The inspection may have happened; if it was not documented and certified, it cannot be proven.
  • Training gaps for affected employees. Maintenance gets the training; operators do not.
  • Skipping verification. Steps 6 and 7 — releasing stored energy and trying to start the machine — are the ones most often shortcut under time pressure, and the ones most often implicated in injuries.
  • Informal lock removal. Cutting off a colleague’s lock without the written procedure.

Penalties adjust annually for inflation. For violations assessed after January 15, 2026, OSHA’s maximum penalties are $16,550 per serious violation and $165,514 per willful or repeated violation, with failure-to-abate assessed at up to $16,550 per day past the abatement date. Because OSHA can cite each unprotected machine separately, LOTO findings compound quickly.

What LOTO Compliance Actually Requires

Every maintenance team knows what lockout/tagout is. Far fewer can produce, on demand, a complete record proving every LOTO procedure was followed, by a trained employee, on the right energy sources, every time — which is exactly what an OSHA inspector or an internal auditor asks for.

Compliance isn’t just “put a lock on it.” The standard requires, among other things:

  • Written, machine-specific energy-control procedures — not a generic template, but documented steps for each piece of equipment with hazardous energy
  • Authorized-employee training and retraining — and records proving who was trained, on what, and when
  • Periodic inspections of each procedure, at least annually, documented and certified
  • Records tying it all together — procedures, authorizations, inspections, and training, retrievable on demand

Notice how much of that is documentation and recordkeeping. The physical act of locking out is the easy part. Proving the program works — consistently, across every asset and every technician — is where teams struggle.

LOTO Compliance Checklist

Use this as a self-audit before an inspector does it for you. If you cannot produce the document behind a line item, treat that line as failed.

Program & Procedures

  • A written energy-control program exists and names who is responsible for it
  • Every machine with hazardous energy has its own written, machine-specific procedure
  • Each procedure lists all energy sources, isolation points, and the method for each
  • Procedures are reviewed and updated when equipment or processes change
  • A written procedure exists for removing a lock when its owner is unavailable

People & Training

  • Authorized, affected, and other employees are identified by name
  • Training records show who was trained, on what, and when
  • Retraining is triggered by job, equipment, or process changes
  • Outside contractors’ procedures have been exchanged and understood

Equipment & Devices

  • Locks and tags are standardized, durable, and used only for LOTO
  • Each authorized employee has individually keyed locks
  • Hasps or group lockboxes are available for multi-person work
  • Devices are available at the point of use, not locked in an office

Inspection & Records

  • Every procedure is inspected at least annually
  • Inspections are certified: machine, date, employees involved, inspector
  • Deviations found in inspection are corrected and the correction recorded
  • Records can be produced on demand, per machine, without a file search

More checklists for maintenance teams are in our library of maintenance checklists.

Why Paper and Spreadsheet LOTO Programs Fail

If your LOTO program lives in binders and spreadsheets, three predictable failures show up.

1. Procedures Go Stale

Equipment changes, someone adds a new energy source, and nobody updates the written procedure — because updating a binder is nobody’s job. The procedure on the wall no longer matches the machine.

2. Records Can’t Be Produced

When an auditor asks for the annual inspection certification on a specific machine, or proof that the technician who serviced it was trained, the answer is a scramble through files — and often, a gap.

3. Nothing Connects

The LOTO procedure, the work order that required it, the technician’s training record, and the inspection log all live in separate places. No single thread proves that the team followed the whole chain for a given service event.

An auditor doesn’t just want to see that you have procedures. They want to see the system working — consistently, with a trail. Paper can’t show that.

Improving Workplace Safety: Mastering Lockout Tagout (LOTO) Procedures

Incorporating Lockout Tagout (LOTO) functionality into Computerized Maintenance Management Systems (CMMS) empowers organizations to efficiently manage LOTO procedures, enhance workplace safety, and promote a safer work environment. With CMMS, teams document and track LOTO activities in one central platform, which in turn enables proper planning and scheduling of maintenance tasks. Real-time visibility into ongoing LOTO tasks allows supervisors to monitor progress and support compliance with safety regulations.

By storing and analyzing historical LOTO data, CMMS facilitates continuous improvement of safety protocols. Furthermore, CMMS integration with employee training modules helps ensure that workers receive proper LOTO training and that certifications and qualifications are appropriately tracked. This technology-driven approach streamlines processes, reinforces a commitment to safeguarding workers from hazardous energy sources, and fosters a culture of safety consciousness throughout the organization.

In practice, that connection shows up in five specific places.

Energy-Control Procedures Live With the Asset

Each machine’s LOTO procedure sits on its asset record — not in a separate binder. Consequently, when the equipment changes, you update the procedure in one place, and everyone sees the current version.

LOTO Is Built Into the Work Order

When a work order requires servicing equipment with hazardous energy, the lockout/tagout procedure is right there in the work order the technician opens. The steps travel with the job — no separate lookup, no guessing which procedure applies.

Training Records Are Tied to Authorization

The system tracks which employees hold training and authorization for which procedures, so you can see — and prove — that the person who did the work was qualified to.

Periodic Inspections Get Scheduled and Documented

You can schedule the annual procedure inspections OSHA requires as recurring preventive maintenance tasks. As a result, they trigger automatically and get certified in the system, rather than sitting forgotten until audit season.

The Audit Trail Assembles Itself

Because the procedure, the work order, the technician, the training, and the inspection all live in one system, the record of a given service event is already connected. When someone asks you to prove compliance, you produce it — you don’t reconstruct it.

Lockout Tagout (LOTO): Safeguarding Workers and Preventing Accidents

Incident reports underscore the sobering reality that many maintenance tragedies could have been averted with the implementation of fundamental lockout/tagout processes. One such incident occurred in August 2012, when Lawrence Daquan “Day” Davis, a 21-year-old temporary worker, lost his life on his first day at Bacardi Bottling Corp. in Jacksonville, Florida. He was cleaning glass from beneath a palletizer’s hoist when another employee restarted the machine.

Investigating the death, OSHA cited the company with two willful violations — for failing to develop lockout/tagout procedures and for failing to train temporary workers on them — along with nine serious violations that included inadequate lockout/tagout devices and insufficient training on energy isolation. Proposed penalties totaled $192,000. The failures were procedural and documentary, not mechanical.

To ensure the well-being of employees and prevent avoidable harm, fostering a safety culture within a plant’s operations is of utmost importance. Emphasizing seemingly obvious processes, such as lockout/tagout, can significantly enhance workplace safety when consistently and conscientiously practiced. By adhering to LOTO protocols, organizations can take tangible steps toward creating a safer working environment and protecting their valued workforce.

Digitizing LOTO isn’t only about passing inspections. It’s about the thing the whole program exists for: making sure a machine can’t start while someone’s hands are inside it. A procedure that’s current, attached to the work order, and only assignable to a trained technician is a procedure that actually gets followed — which is the entire point. The compliance record is a byproduct of a program that works.

What to Look For in LOTO Software

If you’re evaluating how to digitize LOTO, whether with us or anyone else, look for:

  • Energy-control procedures that attach to the asset and surface inside the work order
  • Training and authorization tracking you can tie to who did the work
  • Recurring, documented inspections for the annual review requirement
  • A connected record — procedure, work order, technician, inspection — retrievable on demand
  • A vendor with a real track record in maintenance operations, not a bolt-on afterthought

We’ve been building maintenance management systems for over 30 years, with a 4.9 rating on Capterra and 4.9 on G2.

Conclusion

Implementing lockout/tagout procedures is a paramount step in ensuring the safety of workers, particularly when dealing with hazardous energy sources. Adhering to LOTO standards not only avoids potential fines but, more importantly, prevents injuries and even fatalities in the workplace. To achieve optimal safety, organizations should make the most of lockout and tagout devices, along with utilizing available software, to create a secure work environment where the well-being of employees is prioritized. By embracing these vital safety measures, businesses can cultivate a culture of safety consciousness and protect their most valuable asset — their workforce.

Frequently Asked Questions About Lockout Tagout

What does LOTO stand for?

LOTO stands for lockout/tagout — locking equipment into a de-energized state and tagging it so no one can start it during service. OSHA governs the practice in the U.S. under 29 CFR 1910.147, The Control of Hazardous Energy.

What is the difference between lockout and tagout?

Lockout physically prevents equipment from being energized using a device such as a padlock. Tagout attaches a warning tag that tells people not to operate the equipment. Lockout provides positive protection; tagout only warns, and stands alone only when an energy isolation device cannot accept a lock.

What are the six types of hazardous energy?

Electrical, mechanical, hydraulic, pneumatic, chemical, and thermal. A LOTO procedure must identify and isolate every energy source feeding a machine, including stored energy such as pressure in a hydraulic line or charge in a capacitor.

What are the steps of a lockout tagout procedure?

Preparation, notify affected employees, shutdown, isolation, application of locks and tags, release of stored energy, verification, perform the task, removal of locks and tags, reactivation, and final communication. Steps vary slightly by equipment and workplace.

Who is allowed to perform lockout tagout?

Only authorized employees — workers trained to lock out and tag equipment for service. Affected employees, who operate the equipment, need notification but do not apply the locks. Employers must keep records showing who trained, on what, and when.

What information must a lockout tag include?

A tag should identify why the equipment carries a lockout, who applied it, and when the work should finish. Tags need durability for the environment, a standard format across the facility, and secure attachment so they cannot fall off accidentally.

What is group lockout?

Group lockout applies when more than one person services the same equipment. Each authorized employee applies their own lock, usually via a hasp or a group lockbox, so the machine cannot be re-energized until every worker has removed their own lock.

How often must LOTO procedures be inspected?

OSHA requires a periodic inspection of energy-control procedures at least annually, documented and certified. A CMMS can schedule these as recurring tasks so they are not missed.

What are the most common LOTO violations?

Missing machine-specific written procedures, procedures that no longer match modified equipment, undocumented or missing annual inspections, untrained affected employees, skipping the stored-energy release and verification steps, and informal removal of another worker’s lock.

What are the penalties for LOTO violations?

OSHA penalty amounts adjust annually for inflation. For violations assessed after January 15, 2026, the maximum is $16,550 per serious violation and $165,514 per willful or repeated violation, with failure to abate assessed at up to $16,550 per day past the abatement date. Because OSHA can cite each unprotected machine separately, LOTO findings add up quickly.

Is software required for LOTO compliance?

No — OSHA does not mandate software. But the standard’s documentation, training, and inspection requirements are difficult to meet consistently on paper, which is why many teams move LOTO into a CMMS.

How does a CMMS help with LOTO?

It attaches energy-control procedures to assets, builds them into work orders, tracks training and authorization, schedules and documents periodic inspections, and keeps a connected, retrievable compliance record.

About the author: Janet Jaquis is a CMMS software specialist with over 8 years at eWorkOrders, where she develops educational content, technical guides, and implementation resources for maintenance management professionals. Her work covers preventive maintenance, work order management, asset reliability, inventory management, and CMMS implementation across manufacturing, healthcare, government, food and beverage, and facilities operations, grounded in customer case studies, industry research, and ongoing engagement with the eWorkOrders product team.

Disclaimer: This article provides general information only. It does not constitute legal, professional, or compliance advice. Requirements under 29 CFR 1910.147 depend on your specific equipment, operations, and jurisdiction, and no software makes an organization compliant on its own. We encourage readers to consult the OSHA standard and relevant experts or authorities for specific guidance and implementation of Lockout Tagout (LOTO) procedures in their respective workplaces. The author and publisher of this article are not liable for any actions taken based on the content presented herein.


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