For each machine or installation, all hazardous energy sources and energy isolation points must be identified and documented. This forms the foundation of every LOTO procedure and is often recorded in an Energy Assessment Form.
Developing a Lockout-Tagout Procedure and Work Instruction
What Is a Lockout-Tagout Procedure?
A Lockout-Tagout (LOTO) procedure is the standard method for safely isolating hazardous energy sources before performing maintenance, inspection, troubleshooting, or repair work on machinery and equipment. It prevents unexpected start-up and protects employees from serious injury and potentially fatal incidents.
A LOTO procedure provides step-by-step instructions for shutting down, isolating, locking out, and verifying equipment before work begins.
A comprehensive Lockout-Tagout procedure should include at least:
- Identification of all hazardous energy sources
- Documentation of all energy isolation points
- The correct sequence for equipment shutdown and lockout
- Control of stored or residual energy
- Verification that the equipment is in a zero-energy state
- A safe procedure for returning the equipment to service after work is completed
When the verification step is explicitly included in the procedure, it is often referred to as LOTOTO:
Lock Out – Tag Out – Try Out.
Why Is a LOTO Procedure Manual Necessary?
A LOTO procedure manual forms the foundation of a safe, structured, and repeatable Lockout-Tagout program. Without clearly documented procedures, the risk of human error, unsafe conditions, and incomplete energy isolation increases significantly.
A LOTO manual defines:
- Which machines and equipment are covered by the LOTOTO program
- Which hazardous energy sources are present
- Where all energy isolation points are located
- Which Lockout-Tagout devices and materials must be used
- Who is authorized to perform Lockout-Tagout procedures
- How employees are trained and instructed
- How inspections, audits, and procedure updates are conducted
By implementing a LOTO procedure manual, Lockout-Tagout becomes more than an isolated safety measure. It becomes an integral part of safe maintenance practices, operational safety, and overall risk management.
Step-by-Step Lockout-Tagout Procedure
1. Preparation and Planning
Determine which machine or equipment will be shut down, what work will be performed, which employees are involved, and which hazardous energy sources are present.
2. Identify All Energy Sources
Document all hazardous energy sources associated with the equipment, including electrical, hydraulic, pneumatic, mechanical, thermal, and stored energy.
3. Shut Down and Isolate the Equipment
Perform a controlled shutdown of the equipment and isolate all relevant energy sources using the appropriate energy-isolating devices. An emergency stop alone is not sufficient for energy isolation.
4. Apply Lockout and Tagout Devices
Apply the appropriate lockout devices to each energy isolation point and attach a safety tag to clearly indicate that the equipment must not be operated.
5. Release Stored Energy
Release, disconnect, restrain, or otherwise control all stored or residual energy, such as pressure, spring tension, electrical charge in capacitors, elevated loads, or gravity-related energy.
6. Verify Energy Isolation
Verify that all hazardous energy has been effectively isolated and that the equipment has reached a zero-energy state. This can be confirmed through testing, attempted start-up, measurement, or other approved verification methods.
4. Lockout en Tagout toepassen
7. Lockout Removal and Equipment Restart
Once the work has been completed, authorized employees remove their own lockout and tagout devices. The equipment can then be safely re-energized and returned to service in a controlled manner, following the approved restart procedure.
6. Verificatie van isolatie
How Do You Develop a LOTO Procedure Manual?
A comprehensive LOTOTO manual consists of three essential components that together ensure a safe, standardized, and repeatable Lockout-Tagout process.
Machine and Energy Source Assessment
Roles and Responsibilities
Clearly define responsibilities for procedure execution, lockout removal, training, inspections, and periodic reviews. A clear distinction between authorized employees and affected employees helps prevent errors and improves workplace safety.
Equipment-Specific Procedures
Develop a dedicated LOTO procedure for each machine or installation. The procedure should include identified energy sources, isolation points, required lockout devices, verification steps, control measures, and instructions for safely returning the equipment to service.
Ready to Create Your LOTO Procedure Manual?
Developing a comprehensive LOTO procedure manual requires time and specialist knowledge of machinery, hazardous energy sources, and applicable safety regulations. Using the right templates and expert guidance can significantly streamline the process and help prevent costly mistakes.
To support your implementation, we offer:
- A customizable LOTO procedure template
- Sample Energy Assessment Forms
- Ready-to-use LOTOTO procedure sheets
- Practical guidance for LOTO program implementation
With these resources, you can quickly establish a safe, compliant, and effective Lockout-Tagout procedure for your organization.
Download the LOTO Procedure Template
Get started immediately with a practical, implementation-ready framework for developing your Lockout-Tagout program.
Software for Managing Lockout-Tagout Procedures
In addition to paper-based procedure sheets, we also provide digital solutions for managing, standardizing, and optimizing Lockout-Tagout procedures.
With LOTO software, you can:
- Manage and standardize LOTO procedures from a central platform
- Document machine information and hazardous energy sources
- Visually link energy isolation points to equipment and installations
- Record revisions, audits, inspections, and updates efficiently
- Improve consistency and compliance across multiple sites and departments
We work with leading LOTO software solutions, including:
- Brady LINK360
- Master Lock cLOTO™ solution
- ABUS IMP
These platforms help organizations structure their Lockout-Tagout programs, reduce the risk of human error, and maintain compliance with applicable safety regulations and industry standards.
Need advice on LOTO software? Contact us for a demonstration or tailored consultation.
Standards and Regulations for Lockout-Tagout
Lockout-Tagout Standards and Guidelines
Lockout-Tagout (LOTO) procedures are used to safely isolate hazardous energy sources during maintenance, inspection, servicing, and repair activities on machinery and equipment. Several international standards and regulations define how energy isolation must be performed and how unexpected machine start-up can be prevented.
The most important standards and regulatory frameworks related to Lockout-Tagout include:
Prevention of Unexpected Start-Up
ISO 14118
The standard ISO 14118 – Safety of machinery – Prevention of unexpected start-up specifies measures to prevent machinery from starting unexpectedly during maintenance, cleaning, inspection, and servicing activities.
The standard requires, among other things, that:
- Hazardous energy sources are shut down and isolated
- Energy isolation points can be secured against reactivation
- Employees can verify that the equipment has reached a zero-energy state
- Safe procedures are established for maintenance and servicing activities
Lockout-Tagout systems using safety padlocks, tags, and lockout devices help organizations comply with the requirements of this standard.
Control of Hazardous Energy
OSHA 1910.147
The OSHA standard 29 CFR 1910.147 – The Control of Hazardous Energy (Lockout/Tagout) defines requirements for controlling hazardous energy during maintenance and servicing activities.
This regulation forms the foundation of many Lockout-Tagout programs worldwide and covers, among other things:
- The development of documented LOTO procedures
- The use of personal lockout devices and safety padlocks
- Employee training and competency requirements
- Periodic inspections and audits of Lockout-Tagout procedures
A key principle of OSHA 1910.147 is:
One employee = one lock = one key
Use of Work Equipment
EU Directive 2009/104/EC
Within the European Union, Directive 2009/104/EC concerning the use of work equipment by workers at work establishes requirements for the safe operation and maintenance of machinery and installations.
Employers are required to ensure that:
- Machinery can be shut down safely
- Hazardous energy sources can be isolated
- Maintenance and servicing activities can be performed safely
Lockout-Tagout procedures and energy isolation systems support organizations in meeting these legal obligations and improving workplace safety.
Need Expert Advice on Your Lockout-Tagout Procedure?
We help organizations develop, improve, and implement effective Lockout-Tagout (LOTO) programs. From identifying hazardous energy sources and documenting procedures to selecting the right lockout devices and software solutions, we provide end-to-end support throughout the entire process.
Our services include:
- Developing and optimizing Lockout-Tagout procedures
- Identifying hazardous energy sources and energy isolation points
- Supplying LOTO devices and equipment (ABUS, Brady, Master Lock)
- On-site implementation support and program rollout
- Employee training, competency development, and LOTO audits
As a leading Lockout-Tagout specialist in the Netherlands, we combine expert consultancy, implementation support, training, and safety products to help organizations improve compliance and workplace safety.
Looking for support with your Lockout-Tagout program? Contact our specialists for tailored advice and practical assistance.
Expert Advice
Gain immediate insight into how to develop a safe, compliant, and effective Lockout-Tagout procedure for your organization.
Explore LOTO Products
Discover our complete range of Lockout-Tagout products for every application, industry, and energy isolation requirement.
Download:LOTO Procedure Manual
Get started with a practical LOTO template, example procedures, and guidance for a structured Lockout-Tagout program.
Why Choose Unique Safety Products?
We support organizations across manufacturing, food processing, chemical, and pharmaceutical industries with the development, implementation, and continuous improvement of Lockout-Tagout programs.
What Sets Us Apart
- A unique combination of expert consultancy and Lockout-Tagout products
- Support throughout the entire process, from energy assessments and procedure development to implementation and audits
- Practical software solutions and ready-to-use LOTO templates
- Supply of industry-leading products from ABUS, Brady, and Master Lock
- One of the few providers in the Netherlands offering solutions from all three leading Lockout-Tagout brands
Frequently Asked Questions About Lockout-Tagout (LOTO) Procedures
Lockout-Tagout (LOTO) is a safety procedure used to shut down, isolate, and lock hazardous energy sources on machinery and equipment before maintenance, servicing, inspection, or repair work is performed. This prevents unexpected start-up and protects employees from injury.
A LOTO procedure is required whenever there is a risk of hazardous energy being released unexpectedly during maintenance or servicing activities. Requirements are defined by regulations and standards such as EU Directive 2009/104/EC and OSHA 1910.147.
LOTO stands for Lockout-Tagout.
LOTOTO adds the Try-Out step, which requires verification that all hazardous energy has been effectively isolated and that the equipment is in a zero-energy state before work begins.
All hazardous energy sources must be identified and isolated, including:
- Electrical energy
- Hydraulic energy
- Pneumatic energy
- Mechanical energy
- Thermal energy
- Gas and steam
- Stored energy such as pressure, spring tension, gravity, or electrical charge
LOTO devices are products used to safely lock and identify energy isolation points. Examples include:
- Safety padlocks
- Lockout hasps
- Valve lockout devices
- Circuit breaker lockouts
- Plug lockouts
- Cable lockout devices
- Safety tags and warning labels
These devices help prevent unauthorized operation of equipment during maintenance and servicing activities.
A LOTO procedure is developed by:
- Identifying all hazardous energy sources
- Documenting all energy isolation points
- Defining the correct shutdown and lockout sequence
- Establishing procedures for controlling stored energy
- Verifying energy isolation before work begins
- Creating machine-specific procedure documents
The procedure should be clearly documented and available to all authorized employees.
Only authorized employees who have received appropriate Lockout-Tagout training may perform a LOTO procedure.
Employees who are not authorized must never remove lockout devices or operate locked-out equipment.
LOTO procedures should be reviewed and audited periodically, typically at least once per year, and whenever:
- Machinery is modified
- New equipment is installed
- Energy sources change
- Work processes are updated
- Risks are reassessed
Regular reviews help ensure ongoing compliance, effectiveness, and employee safety.
We help with expert advice, templates, and the right LOTO devices.
