Complete Lockout Tagout (LOTO) Guide: Procedures, Regulations, and Best Practices for Industrial Safety

During machine servicing or maintenance, it is critically important to ensure that equipment cannot be accidentally activated, nor release stored hazardous energy.

To "lock out" and "tag out" a machine before servicing it, designated workers must take a series of safety measures to ensure that the machine does not harm the person performing the service.

What is Lockout Tagout (LOTO) and why is it important?

Lockout / Tagout (LOTO) refers to specific practices and procedures to protect employee safety from the unexpected activation or startup of machines and equipment.

Your plant must have “authorized employees” and “affected employees.” The authorized employee locks out or tags out machines or equipment for the purpose of servicing or maintenance. An affected employee becomes an authorized employee when their duties include performing service or maintenance.

An affected employee is an employee whose job is to operate or use the machine or equipment being serviced or maintained. An "affected employee" can also be one whose job requires them to work in the area where service or maintenance is being performed.

Applicable Regulations: OSHA 29 CFR 1910.147 and NOM-004-STPS-1999

OSHA standard 29 CFR 1910.147 states that employees must be protected from unexpected machine startups. In Mexico, NOM-004-STPS-1999 establishes that a program of procedures for safety protection in machinery must be in place.

LOTO violations are among the most penalized in general industry. Your plant can eliminate this risk by properly implementing a lockout/tagout program with step-by-step instructions for isolating, locking, and tagging all forms of energy supply to machines.

The 5 steps for an effective lockout tagout program

A successful lockout/tagout program starts with a solid foundation and a written plan. After that, proactive training and employee awareness programs will ensure a safer work environment for everyone. Brady has divided the lockout/tagout process into five simple steps, each with effective elements to increase safety in the workplace.

Step 1: Develop and document a written lockout/tagout program

According to OSHA standard 29 CFR 1910.147(c), a written lockout/tagout program must cover at least the following aspects:

• Purpose and scope of the program
• Personnel authorized to perform lockout/tagout
• Compliance policy
• Training methods
• Procedures for group lockout
• Procedures for shift transfer
• Procedures for lockout removal
• Method for auditing and updating lockout procedures
• Coordination with external contractors

Step 2: Graphic lockout procedures for specific machines

Create written lockout procedures for each energized machine. These lockout procedures will serve as a checklist to ensure that employees completely de-energize the machine before servicing, to avoid errors and minimize the risk of accidents or injuries.

The following guidelines must be followed:

• Procedures must be documented and must identify the equipment they cover.
• An individual procedure must be created for each machine that needs to be locked out. There are exceptions where multiple machines can be grouped into a single procedure.
• The procedure must include specific steps for shutting down, isolating, locking, and securing the equipment to control hazardous energy.
• Specific steps for placing, removing, and transferring lockout/tagout devices must also be included.
• The employer must conduct and certify periodic inspections at least once a year.

Step 3: Identification of energy control points.

The third step in a lockout program is to identify all energy control points with cards, labels, or signs. In Section 1910.147(C)(5)(III) ‘IDENTIFICATION OF ENERGY SOURCES’, OSHA requires plants to locate and mark all points for electrical energy isolation (manual switches, circuit breakers, and plugs).

Energy control points must be marked with permanent labels or tags that warn of hazardous conditions if the machine or equipment is activated.

Step 4: Employee training and communication on lockout/tagout.

The fourth step in an effective lockout program is to train employees and promote the implementation of good practices. Ultimately, safety and efficiency can only be achieved through employee training in correct lockout practices.

The regulations state:

• That the employer must provide training to ensure that employees understand the purpose and function of an energy control program.
• The employer must certify that employee training is satisfactorily completed and constantly updated.

There are three categories of employees that require formal lockout training: “Authorized,” “Affected,” and “Other.”

Step 5: Appropriate warning devices and lockout tools

The fifth step to having an effective lockout program is to equip employees with the appropriate lockout tools and warning devices. The proper use of lockout tools is a determining factor for a successful lockout program.

The following are some points to remember when selecting your lockout devices:

• It is necessary to be able to effectively isolate all types of energy at all shutdown points.
• Make sure you have the correct switch, lockout devices for your electrical equipment.
• Make sure you have the correct valve lockout devices for your different valves: gate, ball, and butterfly.

In addition, all authorized employees performing lockout must have exclusive control of the padlocks they use. No worker should be able to open another worker's padlock.

Conclusions

Lockout Tagout (LOTO) is an essential procedure to ensure industrial safety, preventing accidents caused by hazardous energies during machine maintenance.

Complying with international (OSHA 29 CFR 1910.147) and national (NOM-004-STPS-1999) regulations not only prevents penalties but also protects the lives of workers.

A successful LOTO program requires clear documentation, continuous training, precise identification of energy points, and the use of appropriate devices, such as those that ico offers in its Lockout and Tagout section.

The correct implementation of LOTO reduces risks, strengthens the safety culture, and improves operational efficiency in any industrial plant.

Frequently asked questions

1. What is the lockout tagout (LOTO) procedure and what is its main objective?
   LOTO is a set of practices that ensure machines are not accidentally activated during maintenance, protecting workers from hazardous energies.
2. What regulations govern lockout tagout in Mexico and the United States?
   In the U.S., OSHA 29 CFR 1910.147 applies, while in Mexico, NOM-004-STPS-1999 establishes the guidelines for machinery safety programs.
3. What are the key steps to implement an effective lockout tagout program?
   The five steps include: developing a written program, creating machine-specific procedures, identifying energy points, training employees, and using appropriate lockout and warning devices.