Published 8 Sep 2023
What is a Lockout Tagout Procedure Checklist?
A lockout tagout procedure checklist is a tool used by safety officers and managers to ensure that steps are taken to isolate energy sources when servicing industrial equipment or heavy machinery. This is done to protect workers against hazards such as accidental energization of equipment or exposure to hazardous energy.
Millions of machine operators and workers are exposed to risks each day due to non-isolated energy sources; lockout tagout procedure checklists aim to protect workers from those risks.
In this article
- What Should be Included in a LOTO Procedure Checklist?
- Periodic LOTO Inspections
- FAQs about Lockout Tagout Procedure Checklist
- Lockout Tagout Assessment Tool
- Download Free & Customizable Tagout Checklist Templates
What Should be Included 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:
- 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.
- 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 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.
- 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.
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:
- Identify the equipment or isolation point that the LOTO procedure is for
- Specify the date of and the employees included in the LOTO inspection
- Identify and correct the deviations and inadequacies of the LOTO procedure
- Review the responsibilities of authorized and affected employees for lockout, tagout, and training
- 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.
FAQs about Lockout Tagout Procedure Checklist
The purpose of a lockout/tagout checklist is to ensure that:
- Electrical and mechanical functions are de-energized and disengaged;
- Locking and tagging procedures are being complied with;
- Employees are provided individual safety locks and keys;
- All hazards present during the procedure have been managed adequately;
- All necessary details are reported and documented.
Employers are responsible for creating and maintaining the Lockout/Tagout procedure checklist. They must ensure that it is accurate, up-to-date, easily accessible to employees, and reviewed regularly. Involving relevant personnel, such as maintenance staff, safety officers, and supervisors, is essential for developing comprehensive and effective checklists.
Lockout Tagout Assessment Tool
Lockout tagout procedure compliance can be a challenge in the workplace. SafetyCulture (formerly iAuditor) can help organizations better implement safety and compliance in the workplace by providing the tools that safety officers and employees can use to follow LOTO procedures.
With SafetyCulture, you are empowered to:
- Use LOTO checklists conveniently on mobile devices
- Take photos of hazards and record the actions taken to mitigate them during LOTO
- Automatically submit reports on steps taken so far
- Secure recordkeeping using Cloud storage
- Download, edit, and share lockout tagout procedure checklist templates for free
Download Free & Customizable Tagout Checklist Templates
Use this OSHA lockout tagout checklist to assess if lockout tagout procedures are followed by employees before commencing with maintenance checks. With the use of SafetyCulture (iAuditor), you can capture photo evidence of non-compliance with safety regulations while the lockout procedure is ongoing. Notify safety managers if problems occur during the inspection for immediate action and resolution.
This OSHA lockout tagout procedure template can help you check the following:
- Machinery or equipment de-energized or disengaged and locked-out during cleaning or servicing, among others
- Electrical enclosures
- Control circuit also disconnected and locked-out
- Equipment control valve handles locked-out
- Personal safety locks for the employees
- Employees who are working on locked-out equipment by their locks or accompanying tags are identified
- Safe job procedure established and followed
Use this toolbox talk meeting record before performing the lockout/tagout procedure and servicing equipment. Gather the team and discuss what needs to be done before, during, and what to watch out for in order to solve issues before problems occur. Record what was tackled during the LOTO toolbox talk and have all participating members sign off.
A risk assessment is conducted to determine all risks involved in the operation of machines and equipment. Use this risk assessment to identify hazards and determine controls and risk mitigation that can help conduct an effective lockout tagout procedure.
Most workplace incidents and injuries go unreported, making it difficult to identify root causes and prevent future accidents from occurring. Keeping accident logs can help determine if safety measures are strictly followed in the workplace. Use this accident injury checklist to record accidents caused by unisolated energy source and non-adherence to LOTO procedures. Record information of the injured person, injury details, and the contributing factors to the accident. You may also document emergency services involved, hospitalization information, and witness statements. Use SafetyCulture (iAuditor) to compile all accident records for proactive safety planning and accident prevention.