Lockout/Tagout (LOTO) Safety Programs

Lockout/tagout is a safety process used to control hazardous energy by preventing equipment from being turned on during maintenance or servicing. Lockout physically secures the energy source, while tagout provides a warning not to restore power.

• Lockout:

  • Involves turning off and isolating the energy source
  • Uses a lockout device to physically prevent equipment from being operated
  • Ensures energy cannot be restored until the lock is removed

• Tagout:

  • Involves placing a warning tag on the energy source
  • Signals “Do Not Start” or “Do Not Operate”
  • Does not physically prevent operation—it serves as a warning only

Both locks and tags must be durable, resistant to environmental conditions, and designed to prevent unauthorized removal.

Employees must follow the lockout/tagout standard when they perform tasks where unexpected equipment startup or release of stored energy could cause injury. This includes activities involving machines, equipment, or prime movers.

Under Title 8, CCR 3314, the standard applies to employees performing tasks such as:

• Cleaning
• Repairing
• Servicing
• Setting up
• Unjamming
• Adjusting equipment

These requirements are intended to protect workers from injuries caused by unexpected energization, startup, or the release of stored energy during these activities.

Lockout/tagout programs require documentation to verify compliance with hazardous energy control procedures. Employers must maintain records that show inspections, training, and proper procedures are in place.

Required documentation includes:

• Certification of periodic inspections
• Certification of employee training
• documented procedures for the control of hazardous energy

These records demonstrate that the lockout/tagout program is being properly implemented and maintained.

OSHA requires that lockout/tagout procedures be documented in writing, but it does not require the entire energy control program to be in written form. The focus is on ensuring that specific procedures for controlling hazardous energy are clearly documented.

Under 29 CFR 1910.147 and 1910.269, employers must have an energy control program that includes:

• Energy control procedures
• Employee training
• Periodic inspections

However, while these elements are required, OSHA does not mandate that the overall program itself be in writing—only that the procedures for controlling hazardous energy are documented.

A written lockout/tagout procedure must identify the types of hazardous energy involved and clearly outline the steps needed to control that energy safely. This ensures equipment can be properly shut down, isolated, and secured before work begins.

The procedure must include:

• Identification of the types or magnitude of energy to be controlled
• Steps for equipment shutdown
• Methods for equipment isolation
• Instructions for applying lockout/tagout devices
• Processes for releasing stored energy
• Steps for verifying isolation

These elements ensure that hazardous energy is fully controlled to protect employees during servicing or maintenance activities.