February 27, 2025

Lockout/Tagout (LOTO) Procedures: A Step-by-Step Guide to Workplace Safety & Compliance

As industries and companies advance in technology and operations, so too does the need for specialized maintenance operations. Part of the evolution was the system of Lockout/Tagout (LOTO).

This safety procedure helps protect workers from hazardous energy sources during maintenance and repair activities. It involves isolating and securing energy sources through the use of locks and tags, ensuring that employees cannot operate machines and equipment.

In this article, we'll answer the following questions:

⮚ What is Lockout/Tagout (LOTO) and How does It Work?

⮚ How to Implement an Effective LOTO Program in Your Maintenance Department.

⮚ How a CMMS Enhances Lockout/Tagout Procedures.

What is Lockout/Tagout (LOTO) and How does It Work?

In the early 1980s, the American National Standards Institute published practices on lockout/tagout. This guidance aimed to establish safety precautions in handling hazardous energy sources during maintenance. Later in the decade, these measures became regulations under the Occupational Safety and Health Administration (OSHA).

Lockout/tagout ensures the shut off of dangerous machines to make them incapable of unexpectedly releasing hazardous energy or materials during maintenance activities. OSHA's guidelines encompass all potential energy sources, such as mechanical, electrical, hydraulic, pneumatic, chemical, and thermal. These cover many industries.

1. Locks: Physical devices that immobilize energy-isolating devices, such as switches, valves, or breakers. By securing these devices in the off or closed position, you effectively disconnect energy sources.
2. Tags: Warning devices attached to locked energy-isolating devices. These tags provide information about the lockout status, the person responsible for the lockout, and the reason for the lockout. Tags serve as a visual reminder to workers that you've scheduled maintenance for this piece of equipment.

How to Implement an Effective LOTO Program in Your Maintenance Department

Implementing a comprehensive Lockout/Tagout program requires proper planning and execution. To effectively process this activity, consider the following procedural steps.

1. Develop a Written Program: Develop a written Lockout/Tagout program that outlines the procedures and responsibilities. Discuss this with your team. Stay open to feedback and suggestions. Afterward, communicate this plan to all employees.
2. As you'll read later, review and continue to improve the plan.
3. Identify Energy Sources: Conduct a thorough assessment of all energy sources in the workplace. Electrical, mechanical, hydraulic, and pneumatic systems. Don't underestimate the importance of identifying potential hazards. They help determine the appropriate lockout/tagout measures.
4. Train Employees: Establish and implement training opportunities for employees. They should thoroughly understand the lockout/tagout process. This training includes:
• Identifying the energy sources.
• Application of locks and tags.
• The importance of accuracy at each stage.
5. Implement Lockout/Tagout Procedures: At the completion of training implement the procedures.
• Notify affected employees.
• Isolate energy sources.
• Apply locks and tags.
• Verify the stability and de-energized equipment before beginning maintenance or repair work.
6. Regular Inspections and Audits: You need to conduct regular inspections and audits. This ensures employees follow the procedures. Inspections help identify any gaps or areas for improvement. It also aids in the sustainability of the program.
7. Continuous Improvement: Review, discuss, improve, review. Make this an ongoing cycle. Again, accept feedback, document incidents, and read up on industry best practices.

Ready to revolutionize your maintenance department? Schedule a live demo today.

How a CMMS Enhances Lockout/Tagout Procedures

Numerous industries have benefited from CMMS software. Among other aspects, this tool greatly enhances the process of Lockout/Tagout.

Asset Management and Tracking for LOTO Compliance

Asset Management - CMMS software allows organizations to create and maintain an accurate inventory of all equipment and machinery. This information is crucial for identifying potential energy sources and understanding the specific Lockout/Tagout requirements for each asset.

Documenting and Automating LOTO Procedures

Procedure Documentation – Admin supervisors create detailed Lockout/Tagout procedures for each piece of equipment. These might be in the form of checklists or input on a separate document. You'd attach this to the asset record and accompanying work orders.

Admins easily access and update these documents. They're ensuring that workers have the most current and accurate information when performing maintenance tasks.

Improving Training, Access Control, and Compliance with CMMS

Centralized Documentation and Communication: A CMMS provides a centralized platform for documenting and managing lockout/tagout procedures. It allows maintenance departments to store and access all necessary documentation. This includes:

• Equipment-specific lockout procedures.
• Equipment manuals.
• Employee training records.

This ensures that the team has access to the most up-to-date information.

Workflow Automation: CMMS streamlines Lockout/Tagout processes by automating workflow tasks. Supervisors have better work order management and schedules of maintenance activities. The CMMS provides a checklist for step-by-step guidance to execute proper LOTO procedures. Automation helps reduce human error and ensures that technicians consistently follow all necessary steps.

Access Control: With security allowances, supervisors limit access to certain options of the CMMS. This ensures that only authorized employees can initiate or approve Lockout/Tagout procedures.

Training and Certification Tracking – A CMMS tracks employee training and certification related to Lockout/Tagout procedures. This ensures that only qualified and adequately trained personnel execute these critical safety measures. You reduce the risk of accidents.

Real-Time Communication for Lockout/Tagout Safety

Real-time Communication – The system provides a centralized platform for collaboration among maintenance teams. This is particularly beneficial during Lockout/Tagout procedures. You need effective communication to coordinate efforts and ensure that everyone is on the same page.

Enhanced Compliance and Reporting: With a CMMS, maintenance departments can easily track and report on lockout/tagout compliance. The system can generate reports that provide insights into the frequency and effectiveness of lockout/tagout procedures. Supervisors use the reports to identify trends, and areas for improvement, and ensure regulatory compliance.

Integration with Equipment Maintenance: A CMMS can integrate with equipment maintenance modules. This allows maintenance personnel to access lockout/tagout procedures directly from work orders. Integration ensures that lockout/tagout information remains easily accessible. It also reduces the risk of human error in following the correct procedures for specific equipment.

Why Your Business Needs a Lockout/Tagout Program

How important is the implementation of lockout/tagout procedures in your business? Wherever you have the potential for hazardous energy sources, you risk exposure and safety issues. If you don't have an LOTO program in place, consider implementing one.

Failure to comply with LOTO standards could result in fines. Worse, lack of attention poses serious risks of injuries and fatalities. Use tools like lockout and tagout devices along with a CMMS. Maximize workplace safety and protect employees from avoidable harm.

Mapcon / 800-922-4336