Lockout/Tagout Procedure Template (LOTO)

Purpose and Scope

This Standard Operating Procedure (SOP) establishes the energy control program at [Organisation Name], [Site/Location], under 29 CFR 1910.147. It applies to all servicing and maintenance operations where unexpected energization, startup, or stored energy release could cause injury. Covered tasks include clearing jams, cleaning, adjusting, and changing tools whenever employees bypass safety guards or enter equipment danger zones.

This procedure sets the operational framework for machine-specific energy control procedures stored at [Location/System]. Standard machine guarding protects operators during normal production. If routine tasks require bypassing guards or entering danger zones, [Role] must authorize an exception in writing.

Working through related paperwork at the same time? See also our NY Retail Worker Safety Act Policy Template, Job Hazard Analysis Template and OSHA Injury Reporting & Recordkeeping Procedure Template.

Roles and Responsibilities

• Authorized Employees: Trained personnel designated to lock out equipment and perform servicing. [Location/System] maintains the roster of active authorized employees.
• Affected Employees: Operators who run or work around locked-out equipment. Authorized employees must notify them before applying and after removing locks. Affected employees must never try to restart locked-out machinery.
• Other Employees: General staff working in areas where lockout occurs. They must recognize lockout devices and never tamper with or remove them.
• Program Owner ([Role]): Maintains machine-specific procedures, manages device inventory, tracks training records, and schedules annual inspections.

Machine-Specific Procedures and Equipment

Every piece of equipment must have a written energy control procedure registered at [Location/System]. This document details all energy sources (electrical, pneumatic, hydraulic, mechanical, thermal, chemical, and gravity), isolation points, required hardware, stored-energy discharge methods, and zero-energy verification steps. Do not start work without a machine-specific procedure. Report any missing procedure immediately to [Role].

• Lockout Devices: Lockout hardware must be standardized, durable, and used only for energy control. Authorized employees receive personal locks labeled with their names. Only the assigned employee holds the key.
• Lockout Preference: Use locks whenever equipment can accept them. Tagout is allowed only if equipment cannot accept a lock or if the tagout process provides equivalent protection that fully complies with safety standards.
• Hardware Inventory: Hasps, valve covers, breaker blocks, and group lock boxes are stocked at [Location/System]. Replace damaged or missing hardware before starting work.

Energy Control Sequence (Applying Lockout)

1. Preparation: Review the machine-specific procedure at [Location/System]. Identify all energy sources and isolation points, then gather the required lockout hardware.
2. Notification: Notify all affected employees that you are shutting down and locking out the machine for servicing.
3. Shutdown: Turn off the machine using normal stopping controls (such as the stop button or control switch). Let the machine complete its operating cycle first.
4. Isolation: Actuate all energy-isolating devices, open disconnect switches, close valves, or block supply lines, to isolate the machine completely from its energy sources. Never use push buttons or control panel switches as primary isolation points.
5. Lockout Application: Attach personal locks and tags to every isolation point or group lock box. Every authorized employee working on the equipment must attach their own lock.
6. Stored Energy Control: Release, drain, or block all residual or stored energy. Bleed hydraulic and pneumatic lines, discharge capacitors, block or lower suspended parts, and let hot components cool down.
7. Zero Energy Verification: Verify that all personnel are clear. Attempt to start the machine using normal operational controls to confirm it will not run, then turn controls back to “off.” Verify zero energy using test instruments or visual gauges as outlined in the procedure.
8. Work Execution: Complete the scheduled servicing or maintenance.

Release from Lockout (Return to Service)

1. Area Inspection: Check the work area. Remove tools, trash, and loose parts. Confirm machine components are intact and reinstall all guards.
2. Personnel Verification: Verify visually that all workers are safely clear of the machinery and danger zones.
3. Notification: Tell affected employees that you are removing lockout devices and restarting the equipment.
4. Lock Removal: Each authorized worker must remove their own lock and tag. If an employee is absent, only [Role] may remove the lock following the emergency lock-removal procedure.
5. Re-energization: Restore power following the exact steps in the machine-specific procedure. Confirm proper operation before turning the machine back over to production.

Special Circumstances

• Group Lockout: When teams or multiple departments service equipment, use a group lock box or multi-lock device. Each authorized employee must attach their personal lock to the box or device. The lead authorized employee ([Role]) maintains primary responsibility for the lockout.
• Shift Changes: Lockout protection must remain continuous across shift changes. Oncoming authorized workers must attach their personal locks before outgoing workers remove theirs.
• Contractors: Outside contractors and [Organisation Name] must review each other’s energy control procedures before work starts. [Role] coordinates contractor work and explains contractor lockout devices to affected employees.
• Cord-and-Plug Equipment: Cord-connected tools and equipment are exempt from formal lockout if unplugging them removes all power and the plug stays under the exclusive, continuous control of the technician (or is locked out with a plug lock).

Training and Periodic Inspections

• Training Requirements: Authorized employees must complete training on energy control procedures, hazard types, and isolation methods before performing maintenance. Retrain employees whenever equipment, procedures, or job duties change, or if inspections reveal gaps in execution. Train affected and general employees to recognize lockout hardware and understand why restarting locked-out gear is strictly prohibited.
• Periodic Inspections: An authorized employee who does not use the procedure must inspect each machine-specific procedure at least annually. The inspector must observe an active lockout sequence, correct any errors, review responsibilities with the team, and complete a written certification (listing the machine, date, employees observed, and inspector) at [Location/System].

Records and Review

• Recordkeeping: [Location/System] stores all machine-specific procedures, training logs, annual inspection certifications, hardware inventories, and emergency lock-removal records for [Retention Period].
• Review Cycle: Review this SOP and all machine-specific procedures [Frequency, e.g., annually], after any near-miss or energy control incident, or whenever new equipment arrives on site.

Program Owner: [Role] Document Approval Date: [Date] Next Review Date: [Date]