Every year, failure to control hazardous energy results in nearly 120 fatalities and 50,000 injuries in workplaces across the world. What's more shocking? Most of these tragedies could have been prevented by following one simple procedure: Lockout Tagout (LOTO). Whether you're a safety manager, maintenance technician, or facility owner, understanding and implementing proper Lockout steps isn't just good practice—it's the law. OSHA's standard 1910.147 requires it, and for good reason: it saves lives.

In this comprehensive guide, we'll walk you through the 6 essential Lockout Tagout steps that form the foundation of any successful energy control program.

What is Lockout Tagout and Why Does It Matter?

Lockout Tagout is a safety procedure that ensures dangerous machines are properly shut off and unable to be started up again before maintenance or servicing work begins. It involves:

• Lockout: Placing a lock on an energy-isolating device

• Tagout: Attaching a warning tag to the lock

This simple two-part process creates a physical barrier and warning system that protects workers from unexpected energization, startup, or release of stored energy.

The 6 Crucial Lockout Tagout Steps

Step 1: Preparation - Know Your Equipment

Before any shutdown begins, the authorized employee must:

• Identify all energy sources (electrical, pneumatic, hydraulic, etc.)

• Understand the magnitude of energy and potential hazards

• Know the proper methods to control each energy source

• Notify all affected employees that equipment will be shut down

Pro Tip: Create machine-specific procedures that document every energy source and its isolation point.

Step 2: Shutdown - Power Down Properly

• Follow the equipment's normal shutdown procedure

• Use all manufacturer-recommended methods

• Ensure all moving parts have come to a complete stop

Why This Matters: Proper shutdown prevents damage to equipment and reduces residual energy.

Step 3: Isolation - Cut Off All Energy Sources

This is where the actual "lockout" begins:

• Locate and operate all energy isolation devices

• This includes electrical disconnects, valves, blocks, and blanks

• Verify that each device completely isolates the energy source

Common Mistake: Missing secondary or hidden energy sources like capacitors or gravitational energy.

Step 4: Lockout/Tagout Application - Secure the Isolation

• Apply your lock and tag to each energy-isolating device

• Use only authorized, standardized locks and tags

• Each worker involved must apply their own personal lock

• Tags must clearly show: "DO NOT OPERATE," the worker's name, date, and reason

Critical Point: Never rely on tags alone—always use physical locks whenever possible.

Step 5: Stored Energy Release - Eliminate Hidden Dangers

Even after isolation, equipment may still contain hazardous stored energy:

• Release or block spring energy

• Bleed hydraulic and pneumatic lines

• Drain fluids and gases

• Block elevated parts

• Discharge capacitors

Safety Check: Verify all energy has been dissipated using appropriate testing equipment.

Step 6: Verification - The Final Safety Check

Before starting work:

• Ensure all personnel are clear of danger zones

• Attempt to start the equipment using normal controls

• Verify the equipment cannot start or move

• Test voltage with appropriate meters

Golden Rule: Always test before you touch!

Restoration: The Often-Forgotten 7th Step

While not technically part of the lockout procedure, equipment restoration is equally important:

1. Ensure equipment is properly reassembled

2. Confirm all tools and personnel are clear

3. Notify affected employees before removing locks

4. Remove locks and tags in reverse order (last on, first off)

5. Energize and test equipment operation

We are Innovern Engineering providing one stop solution for Lockout Tagout (LOTO), including lockout tagout product, assessment, consultancy and lockout tagout procedure.