Why Your Lockout/Tagout Procedure Might Be Missing the One Thing That Keeps Everyone Alive
If your team’s lockout/tagout training is a dusty checklist taped to the breakroom fridge, we’ve got some bad news. Safety isn’t a suggestion, and when it comes to hazardous energy, “good enough” just doesn’t cut it.
Lockout/tagout (LOTO) is the difference between going home at 5 and going to the ER. The problem? Too many workplaces treat it like a formality, not a lifesaving system. In this blog, we’re diving deep into the six steps of LOTO, why each one matters more than you think, and how to train your crew so they don’t just know the steps, they believe in them.
Step one: prep like someone’s life depends on it (because it does)
Before anyone touches a wrench, presses a button, or pops open a panel, they need to prep. And we don’t mean skimming yesterday’s work order while sipping coffee. We’re talking full-blown hazard assessment.
This is where your authorized employee (yep, that’s a real role) identifies every source of hazardous energy that needs to be controlled, electrical, mechanical, hydraulic, thermal, you name it. You can’t lock out what you don’t understand. The prep stage is all about asking the right questions:
- What kinds of energy are involved?
- Where is it stored?
- How is it released?
- What could go wrong if we skip a step?
Sloppy prep leads to sloppy shutdowns, and in this line of work, “sloppy” is a dangerous word.
Step two: shut it down and speak up
Now that you know what you’re dealing with, it’s time to shut it all down. Completely. This isn’t the moment for halfway measures or hoping a blinking light means it’s off. Power off the machine or equipment completely and clearly communicate with anyone affected, even if they’re just walking by.
Why? Because confusion is chaos, and chaos gets people hurt. A solid shutdown means notifying every potentially affected employee that the equipment is going offline and why. They don’t need to know all the details, but they do need to know not to mess with it.
Step three: isolate every energy source like it’s trying to trick you
Isolation sounds obvious, but here’s where many teams get cocky. You didn’t just shut the thing down, you need to physically separate it from its energy sources. That could mean turning off circuit breakers, closing valves, unplugging cords, or blocking pressure lines.
Think of energy like a horror movie villain. Just because it’s quiet doesn’t mean it’s gone. Unless every energy source is fully cut off and neutralized, you’re not safe.
Step four: lock it, tag it, and make it yours
Here’s the iconic moment, the part where the padlock and tag come out. But this isn’t just for show. The lock is a physical barrier, and the tag is a loud, visual warning. Together, they send a message: “Do not touch. This could kill someone.”
The lock must go on each energy-isolating device in a way that can’t be overridden without serious effort. And the tag? It better have your name on it. The person who does the lockout should be the one who removes it. Period.
This isn’t bureaucracy. It’s accountability. And it saves lives.
Step five: Don’t forget about stored energy, it’s sneaky
Here’s the twist no one sees coming: even after you’ve shut it all down and locked it up, there could still be dangerous energy trapped inside. Think of compressed springs, charged capacitors, steam pressure, or hydraulic buildup. This is the “residual energy” step, and skipping it is like cutting the red wire without checking the rest of the bomb.
Your job now is to release, drain, bleed, or block every bit of that stored energy. Don’t assume the lock makes it safe. Verify it.
Step six: verify, then verify again (yes, really)
You’re almost there. But before anyone lays a hand on the machine, you need to double-check that it’s truly, completely, and undeniably safe. That means testing controls to make sure the machine won’t start. That means confirming every source of energy is de-energized. That means taking five more minutes to prevent a catastrophe.
Verification isn’t overkill. It’s the difference between a job well done and an obituary no one saw coming.
Wait, who’s actually supposed to know all this stuff?
LOTO isn’t just for the authorized employees doing the work. Affected employees need to know when not to touch something. Supervisors need to know how to enforce it. And safety managers? You need to be the glue holding it all together.
This is why ongoing, legit training matters. Not a quick slideshow. Not a ten-minute quiz. We’re talking full-on, immersive, OSHA-aligned training that makes your team think, remember, and act like safety leaders.
So, how do you actually teach this without putting people to sleep?
You’ve got options, lots of them. We cover:
- What lockout/tagout actually is (and isn’t)
- Who qualifies as an authorized or affected employee
- Employer and employee responsibilities
- Types of energy and energy control devices
- Tagout limitations
- When to retrain (hint: it’s probably more often than you think)
Plus, it’s all OSHA-compliant, so you can train without wondering if your program holds up under inspection.
Already nailing LOTO? Let’s take it further with this.
If you’re already training your team on lockout/tagout, now’s the perfect time to plug in another essential layer of safety: Electrical Safety Training. Because the second most dangerous thing after stored energy… is assuming you know how to handle it. Teach your team to respect volts the way they respect locks.
Expand your knowledge with Lockout/Tagout: Secure Safely Training Course.
This course provides an introduction to lockout/tagout procedures, but there’s more to learn. For a deeper understanding of energy control, workplace responsibilities, and real-world scenarios, consider enrolling in our Lockout/Tagout: Secure Safely Training Course.
References
- Occupational Safety and Health Administration (OSHA) – Lockout/Tagout (Control of Hazardous Energy).
- Centers for Disease Control and Prevention (CDC) – NIOSH Lockout/Tagout Resources.
- Department of Labor (DOL) – Lockout/Tagout Topic Page
