Lockout/Tagout (LOTO) procedures are essential for safely isolating and de-energizing machinery and equipment during maintenance or repair. These procedures prevent accidental startup or the release of hazardous energy, protecting workers from serious injury or death. Failure to control hazardous energy accounts for nearly 10 percent of serious accidents in many industries. [1]

Here are the general steps for an effective LOTO procedure:

1. Prepare for Shutdown: Identify the machine, equipment, or process that requires lockout, the energy sources present, and the necessary lockout devices.
2. Notify Affected Personnel: Inform all affected personnel about what is being locked/tagged out, why, the expected duration, who is responsible, and who to contact for more information. This information should also be on the tag.
3. Equipment Shutdown: Follow established shutdown procedures, ensuring controls are in the off position and all moving parts have come to a complete stop.
4. Isolation of System (De-energization): Follow the lockout procedure for the specific machine, equipment, or process. This involves switching electrical disconnects to the off position and visually verifying the breaker connections are in the off position. Lock the disconnects into the off position.
5. Dissipation (Removal) of Residual or Stored Energy: Relieve, disconnect, restrain, or render safe any potentially hazardous stored or residual energy. Examples include discharging capacitors, bleeding hydraulic or pneumatic lines, and blocking parts that may move due to gravity or spring energy.
6. Lockout/Tag Out: Apply lockout devices to energy-isolating devices to hold them in a safe or off position. If a lockout device cannot be used, a tagout device must be used instead. Tags must clearly indicate that operation or movement of energy-isolating devices is prohibited.
7. Verify Isolation: Verify that the system is properly locked out before beginning any work. This can be done by engaging or activating the machine, equipment, or process controls and observing that there is no response. Return controls to the safe position (off).
8. Perform Maintenance or Service Activity: Complete the necessary maintenance or service activity.
9. Remove Lockout/Tag Out Devices: Inspect the work area to ensure all tools and items have been removed, confirm all employees are safely located away from hazardous areas, verify that controls are in a neutral position, remove devices in the opposite order in which they were installed, and re-energize the system. Notify affected employees that servicing is completed.

[2] [2] [2] [2] [6] [7] [8] [3] [3] Key aspects of a LOTO program include:

• Identifying hazardous energy types, energy-isolating devices, and de-energizing devices.
• Providing proper training to authorized and affected employees.
• Describing specific lockout procedures for all machines, equipment, and processes.
• Specifying shutdown, de-energizing, energizing, and start-up sequences.
• Auditing the program for effectiveness.

[5] [4] [4] [4] [4] Remember, LOTO is not just about putting a lock on a switch; it's a comprehensive process involving communication, coordination, and thorough training to ensure worker safety.