Lockout/tagout (LOTO) procedures are essential for machinery maintenance and hazardous energy control. LOTO ensures that machines are isolated from their energy source and rendered inoperative before any servicing or maintenance work begins. This prevents unexpected energization, start-up, or release of stored energy that could cause injury to employees. [7] [10] [13]

Key components of lockout/tagout procedures include:

• Energy Control Program: Employers must establish a comprehensive energy control program that includes LOTO procedures, employee training, and periodic inspections.
• Lockout/Tagout Procedures: Procedures must be developed, documented, and utilized for the control of potentially hazardous energy.
• Protective Materials and Hardware: Employers must provide necessary hardware for isolating, securing, or blocking machines from energy sources, such as locks, tags, chains, and self-locking fasteners.

[7] [4] [12] The general steps for LOTO include:

• Preparation for shutdown: Know the type and magnitude of the energy, hazards, and control methods.
• Machine or equipment shutdown: Use established shutdown procedures to avoid additional hazards.
• Machine or equipment isolation: Locate and operate energy-isolating devices to isolate the machine from energy sources.
• Lockout or tagout device application: Affix devices to each energy-isolating device by authorized employees.
• Stored energy: Relieve, disconnect, restrain or render safe all potentially hazardous stored or residual energy.
• Verification of isolation: Verify isolation and de-energization before starting work.

[5] [5] [5] [5] [8] [8] OSHA also specifies requirements for LOTO devices:

• Durability: Devices must withstand the environment they are exposed to.
• Standardization: Devices shall be standardized within the facility by color, shape, or size.
• Substantiality: Lockout devices must prevent removal without excessive force.
• Identifiable: Devices must indicate the identity of the employee applying the device(s).
• Warning: Tagout devices must warn against hazardous conditions.

[3] [3] [3] [6] [6] Periodic inspections of energy control procedures must be done at least annually to ensure the procedure and requirements are being followed. These inspections must be performed by an authorized employee not utilizing the energy control procedure being inspected. [6] [6]

Training and communication are also key. Training should ensure that the purpose and function of the energy control program are understood by employees and that they have the knowledge and skills for the safe application, usage, and removal of energy controls. [14]

Specific training requirements include:

• Each authorized employee must receive training in the recognition of applicable hazardous energy sources, the type and magnitude of the energy available, and the methods for energy isolation and control.
• Each affected employee must be instructed in the purpose and use of the energy control procedure.
• All other employees whose work operations are or may be in an area where energy control procedures may be utilized, must be instructed about the procedure, and about the prohibition relating to attempts to restart or reenergize machines or equipment which are locked out or tagged out.

[14] [14] [14] Retraining must be provided whenever there are changes in job assignments, machines, equipment, processes, or energy control procedures. Additional retraining is required whenever a periodic inspection reveals deviations or inadequacies in an employee's knowledge or use of energy control procedures. [9] [9]

During shift or personnel changes, specific procedures shall be utilized to ensure the continuity of lockout or tagout protection, including an orderly transfer of LOTO device protection between off-going and oncoming employees. [11]

When servicing and/or maintenance is performed by a group, a procedure must be used that provides a level of protection equivalent to that of a personal lockout or tagout device. One authorized employee must be vested with primary responsibility for a set number of employees, and must ascertain the exposure status of individual group members. Each authorized employee should affix a personal lockout or tagout device to the group lockout device. [1] [1] [1] [1]

Before removing lockout or tagout devices and restoring energy, the work area must be inspected to ensure nonessential items have been removed and machine components are intact. Affected employees must be notified that the devices have been removed. [8] [2]

Each lockout or tagout device shall be removed by the employee who applied it. [2]