Lockout Tagout Procedure Checklist

What to Include in a LOTO Procedure Checklist

Lockout tagout procedures can vary depending on the industry or type of machine or equipment. Following OSHA lockout tagout procedure standards by using a procedures template and safety checklist will help ensure that all dangerous machinery and equipment are properly shut off, locked out, and tagged before performing maintenance checks. OSHA estimates that complying with LOTO standards helps prevent 120 fatalities and 50,000 injuries each year. Here are the main sections of a lockout tagout procedure checklist:

Machine/equipment information

• Identify the machine or equipment that will be shut down and record the purpose of the lockout/tagout such as maintenance or repair.
• Identify the energy sources that could cause harm if not isolated such as electrical, mechanical, hydraulic, pneumatic, chemical, thermal, etc.

Area inspection

• Check if the area surrounding the equipment has no items that could pose a risk to the workers during equipment maintenance.
• Employees who are not going to work on the maintenance should also clear the area.

Employees

• Employees are made aware of their responsibilities during the LOTO and maintenance of the machine.
• Employees should be informed that a machine or equipment is about to be serviced and that a lockout tagout procedure is being performed.

LOTO devices

• Ensure that the proper LOTO devices are available for the job.
• The responsible persons who will apply the devices should be identified.

Applying LOTO devices

• Primary and possible secondary sources of energy should be identified and de-energized.
• Ensure that all sources of power are isolated before the proper LOTO devices are applied to each energy-isolating device.
• Lockout the machine or equipment, ensure that shut off is verified and that employees know that it is out of service at the moment.

Removing LOTO devices

• Clear all the tools and place back machine guarding.
• LOTO devices are to be removed by the person who applied them.
• Restore energy to the machine or equipment.
• Inform all the affected employees that the machine or equipment is back in operation.

7 Steps of Lockout Tagout Procedure

Here are the steps to the proper lockout tagout procedure:

• Step 1: Identify and assess – Determine the equipment to shut down, control energy sources, and evaluate hazards.
• Step 2: Notify personnel – Inform affected staff about the shutdown, including details, timeframe, and contacts.
• Step 3: Shut down equipment – Follow proper procedures to turn off controls and stop all moving parts.
• Step 4: Disconnect energy sources – Isolate the equipment by shutting off power breakers or closing valves.
• Step 5: Remove residual energy – Neutralize stored energy to eliminate potential hazards.
• Step 6: Lock and tag equipment – Secure the equipment with locks and tags displaying identifying information.
• Step 7: Verify isolation – Test controls to confirm the equipment does not activate.

Know more about these steps in this comprehensive guide to the Lockout Tagout procedure.

Periodic LOTO Inspections

A LOTO inspection can only be conducted by a safety supervisor or authorized employee who is NOT involved in the lock out tag out procedure being inspected. To conduct a LOTO inspection, the safety supervisor or authorized employee must do the following:

1. Identify the equipment or isolation point that the LOTO procedure is for
2. Specify the date of and the employees included in the LOTO inspection
3. Identify and correct the deviations and inadequacies of the LOTO procedure
4. Review the responsibilities of authorized and affected employees for lockout, tagout, and training
5. Verify that you have conducted the LOTO inspection by adding your name and signature

LOTO inspections must be conducted at least annually or more often if necessary.