What is Lockout/Tagout? Understanding Its Importance in Workplace Safety

Lockout/Tagout (LOTO) is a vital safety procedure designed to prevent accidents when working with hazardous energy. This system ensures that dangerous equipment is properly shut down and cannot be started again until all maintenance or repair work is completed.

Key Takeaways

• LOTO is a critical practice for preventing serious accidents during equipment maintenance and servicing.
• Compliance with applicable Canadian standards and regulations is essential for any LOTO program.
• Proper training, clear procedures, and routine audits are what turn a LOTO program from paperwork into real workplace safety.

Understanding Lockout/Tagout

Definition and Importance

Lockout/Tagout refers to specific safety practices used to control hazardous energy during equipment maintenance and repair. It involves isolating energy sources and securing equipment in a safe state before any work begins.

Lockout devices, such as padlocks, physically prevent machine activation. Tagout devices, such as warning tags, inform workers that equipment must not be operated. Used together, they protect workers from unexpected start-up or release of stored energy.

Key Components and Terminology

• Energy-Isolating Device: Any device that physically disconnects an energy source, such as switches, circuit breakers, or valves.
• Lockout Devices: Devices that hold energy-isolating devices in a safe position so the equipment cannot be re-energized.
• Tagout Devices: Visible warnings indicating that equipment should not be operated until the tag is removed by an authorized person.

Energy Control Programs

Developing an Energy Control Program

An effective energy control program is built on a few core steps:

• Identify all machinery and equipment that pose a risk due to hazardous energy.
• Establish written procedures for isolating each energy source.
• Train employees on those procedures and confirm competency.
• Include regular audits to confirm the program is being followed in practice.

Compliance with CCOHS Standards

Organizations must develop procedures that meet the standards published by the Canadian Centre for Occupational Health and Safety (CCOHS) and applicable CSA standards such as CSA Z460. This includes proper use of lockout devices alongside tagout devices, training workers on why those standards exist, and conducting periodic reviews to ensure ongoing compliance.

Procedure and Application of LOTO

Lockout/Tagout Procedures

Every LOTO event begins with a documented shutdown procedure. Once the equipment is shut down, isolation must be verified by disconnecting the equipment from its energy sources. A lock and tag are then affixed to each energy-isolating device. Regular audits help ensure the procedures match what workers are actually doing on the floor.

Steps for Safe Lockout/Tagout

1. Shutdown the equipment using the normal stopping procedure.
2. Isolate all energy sources, including electrical, hydraulic, pneumatic, and stored energy.
3. Lock out and tag each energy-isolating device.
4. Verify isolation by attempting to start the equipment with the controls.
5. Perform the maintenance or repair tasks safely.
6. Remove locks and tags only after ensuring everyone is clear of the equipment.

Roles and Responsibilities

Authorized, Affected, and Other Employees

Authorized employees have permission to apply LOTO devices and handle maintenance on the equipment. Affected employees operate the machines that are being locked out and must be informed about the lockout status. Other employees in the vicinity should also be aware of the program so they understand why equipment is tagged and avoid interfering.

Training Requirements

Authorized employees need detailed training on locking and tagging equipment, recognizing energy sources, and understanding each procedure. Affected employees need basic training on LOTO principles and what locked-out equipment looks like. Employers must regularly review and update training as procedures, equipment, or hazards change.

Preventing Workplace Injuries

Risk Assessment and Safety Measures

A thorough risk assessment should be conducted before any maintenance task begins. Inspect the equipment, evaluate the surrounding environment, clearly mark the maintenance area, and apply LOTO procedures to control every relevant energy source.

Equipment and Personal Safety

Common PPE used during LOTO work includes helmets, gloves, and goggles. Safety devices such as emergency stops and machine guards add additional protection. Regular maintenance of those safety devices, paired with training on safe equipment use, is essential.

Frequently Asked Questions

1. What are the steps in a proper Lockout/Tagout procedure?

Notify affected employees, shut down the equipment using normal procedures, isolate every energy source, apply locks and tags to each isolation point, release or restrain stored energy, and verify isolation before any work begins. Locks and tags are only removed once work is complete and the area is clear.

2. What items should be in a complete LOTO kit?

A complete kit typically includes padlocks, hasps, lockout tags, valve lockout devices, electrical plug lockouts, breaker lockouts, and a labelled storage box or station. Kits should be tailored to the specific energy sources at the facility.

3. What is the purpose of implementing a LOTO program?

The purpose is to prevent the unexpected energization, start-up, or release of stored energy that could injure workers performing servicing or maintenance. A documented program is also a legal expectation under Ontario's OHSA and CSA Z460.

4. When is LOTO required?

LOTO is required any time a worker performs servicing or maintenance where unexpected energization or release of stored energy could cause injury. Common examples include clearing jams, performing repairs, cleaning machinery with guards removed, or adjusting equipment.

5. Who is authorized to perform LOTO and what training is required?

Only employees who have been formally trained and designated as authorized may apply LOTO devices. Their training must cover energy source recognition, isolation methods, procedure application, and verification steps. Affected and other employees require awareness training appropriate to their role.

6. What are the risks of failing to follow LOTO procedures?

Failure to follow LOTO procedures can result in serious crush injuries, electrocutions, amputations, and fatalities. Beyond the human cost, organizations face Ministry of Labour orders, significant fines, and reputational damage.

Need Health and Safety Help?

Get in touch with us to discuss your LOTO program. Contact CCL Health & Safety to start a conversation, or learn more about our Lockout/Tagout consulting services.