Safe use of machinery is non-negotiable in any industrial or maintenance setting. One of the most critical procedures to protect workers from serious injuries—or fatalities—is the Lockout/Tagout (LOTO) system.
LOTO is a safety protocol designed to ensure machinery is properly shut off and cannot be restarted until maintenance or servicing is complete.
Improper or incomplete Lockout/Tagout procedures are among the top violations cited by safety regulators like OSHA and provincial health and safety authorities. Mastering LOTO isn’t just a matter of compliance—it’s a matter of life and death.
What Is Lockout/Tagout?
Lockout/Tagout is a safety procedure used to ensure that dangerous machines are properly shut off and not able to be started up again prior to the completion of maintenance or servicing work.
- Lockout involves physically locking the energy-isolating device in the “off” position with a lock.
- Tagout involves attaching a tag to the lockout device indicating who locked the system, why, and when.
These steps prevent the unexpected startup or release of hazardous energy—whether electrical, mechanical, hydraulic, pneumatic, chemical, or thermal.
Why Is Lockout/Tagout Important?
The consequences of ignoring Lockout/Tagout can be devastating. Accidental machine startups or energy releases can cause:
- Crushed limbs
- Amputations
- Electrocution
- Burns
- Death
According to OSHA, compliance with LOTO standards prevents an estimated 120 fatalities and 50,000 injuries annually in the U.S. In Canada, both CCOHS and provincial regulators such as WorkSafeBC emphasize LOTO as a critical safety requirement. (DoFollow links)
Key Elements of a Lockout/Tagout Program
An effective Lockout/Tagout program consists of several essential components. All workplaces that involve machine servicing or maintenance must ensure:
1. Written Lockout/Tagout Policy
A clear, written procedure that outlines when and how to perform LOTO, and who is authorized to do so.
2. Employee Training
Training must be provided to:
- Authorized employees (those who perform LOTO)
- Affected employees (those who operate or work near equipment)
- Other employees who may work in the area
3. Lockout Devices and Tags
Use durable, standardized, and identifiable locks and tags. Each authorized worker should have their own lock and key.
4. Step-by-Step Procedures
For each machine, document specific lockout points, shutdown steps, energy release methods, and verification tests.
5. Periodic Inspections
At least annually, a supervisor or safety officer must review each procedure with authorized personnel to ensure effectiveness and compliance.
The 6 Essential Lockout/Tagout Steps
- Prepare for Shutdown
Know the types of energy involved and how to control them safely. - Shutdown the Equipment
Turn off the machine using normal procedures. - Isolate the Energy Source(s)
Turn off power at circuit breakers, valves, switches, etc. - Apply Lockout/Tagout Devices
Place locks and tags on all energy-isolating devices. - Release Stored Energy
Bleed air, drain fluids, release springs—ensure zero-energy state. - Verify Isolation
Try to turn on the equipment to confirm it’s completely de-energized.
Only after these steps can maintenance or servicing safely begin.
Common Lockout/Tagout Mistakes to Avoid
Even well-meaning workplaces can fall into dangerous habits. Some of the most frequent LOTO failures include:
- Forgetting to verify zero-energy state
- Using the wrong type of lock or tag
- Allowing shared keys (compromising lock integrity)
- Failing to retrain employees after procedure changes
- Assuming electrical isolation is sufficient without addressing other energy types
Avoiding these errors requires ongoing training, leadership enforcement, and a strong safety culture.
Legal Requirements and Compliance in Canada
Under most provincial and territorial regulations in Canada (such as Ontario Regulation 851 for Industrial Establishments), employers must:
- Establish energy control procedures
- Train workers on LOTO procedures
- Supply appropriate lockout devices
- Review programs regularly
- Document and retain lockout inspections
Failure to comply can lead to fines, criminal charges, or tragic workplace incidents.
More info: OHSA Canada Guidelines
Building a Culture of Machine Safety
Lockout/Tagout is not just a checklist—it’s a mindset. Building a safe use of machinery culture requires:
- Visible leadership support
- Worker empowerment to speak up if LOTO is skipped
- Regular drills and audits
- Recognition and rewards for safe behavior
Include lockout/tagout reminders in your regular Toolbox Talks, and reinforce LOTO during onboarding and refresher sessions.
Explore more toolbox talk ideas at OHSE.ca. (Internal link)
Conclusion: Lockout/Tagout Saves Lives
Safe use of machinery starts with controlling energy at its source. A strong Lockout/Tagout system eliminates guesswork, removes hazards, and empowers workers to protect themselves and their coworkers.
It’s not enough to have the tools—you must build the culture and training that make LOTO second nature.
Make Lockout/Tagout part of your OHSE foundation today—and prevent tomorrow’s tragedy.
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