Lockout/Tagout: Easy to do but too easy to forget?
November 25, 2025
We all recognize lockout/tagout (LOTO) as a necessary protection system that guards against unintentional exposure to hazardous energy from equipment and machinery. The lockout device secures the device and the tagout warns employees to not use the equipment until it’s removed. Sounds easy enough. But, unfortunately, the protocols aren’t always followed carefully or at all.
Why LOTO can still leave workers at risk for severe injuries or even fatalities:
- Lack of training — can lead to complacency or rushing the process
- Failure to identify all devices and energy sources
- Not draining residual energy from devices
- Failure to verify that protocols have been followed
- Misuse of locks and/or tags
- Duplicate keys – Too many workers with access
Without a well-defined LOTO process, your employees may not know the locations of all of the dangers posed by uncontrolled hazardous energy or who is responsible for doing what and when.
We’ve found seven key steps to designing and maintaining a successful LOTO procedure:
- Preparation – Develop a system to identify the device and develop a shutdown procedure
- Notification – All personnel involved need to be notified when a shutdown occurs
- Shutdown – Turn off all controls and ensure all running parts have stopped completely
- Isolation – De-energize the energy source
- Dissipation – Remove any potential residual energy that may still be in the equipment
- LOTO – Lock the device using energy isolating devices and attach the tag
- Verification – Re-check the LOTO to ensure all procedures have been followed
OSHA has resources to help you with design, training, and ongoing protocols for your LOTO program. This link will also lead you to the specific OSHA regulations governing LOTO.
