⚡ LOCK OUT TAG OUT (LOTO): The Rule That Prevents “It Started By Itself”

 🔒⚡ LOCK OUT TAG OUT (LOTO): The Rule That Prevents “It Started By Itself”

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Machines can restart without warning. A hidden spring can snap back. A valve can creep open.

LOTO stops all of that—by isolating energy before anyone puts hands on a machine.

What LOTO Means (in plain words)❓

♦️Lockout: Put a physical lock on the energy source so it can’t be turned on.

♦️Tagout: Hang a warning tag that says who locked it and why it must not be operated.

Where LOTO Applies----

▪️Any time you service, clean, unjam, inspect, or repair equipment that could move, shock, burn, crush, or release pressure.

▪️Energy sources to control: electrical, mechanical, hydraulic, pneumatic, chemical, thermal, gravity, springs, stored/“residual” energy, and even multi-energy systems.

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📌 The 8 Golden Steps (remember: Shut it. Lock it. Tag it. Test it.)

1. Prepare – Know the machine, all energy sources, and the procedure.

2. Notify – Tell affected workers what’s happening and for how long.

3. Shut Down – Turn the equipment OFF using normal controls.

4. Isolate – Open disconnects/valves; block or bleed lines; secure moving parts.

5. Lock & Tag – Each person applies their own lock + readable tag. No shared keys.

6. Release Stored Energy – Discharge capacitors, bleed pressure, block gravity, secure flywheels/springs.

7. Verify Zero Energy – Try-start or test with a meter after isolation (then return controls to off).

8. Do the Work – Stay within the locked-out boundary.

When done: clear tools/people, remove locks personally, re-energize, and inform everyone.

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🔖 Roles & Responsibilities

▪️Authorized workers (maintenance/technicians): follow the written LOTO procedure, use proper devices, verify zero energy, keep the key.

▪️Affected workers (operators/nearby staff): respect locks/tags, never touch controls, keep clear.

▪️Supervisors: make sure procedures exist, devices are available, and audits/training are done.

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Do’s ✅

▪️Use the right device: breaker lockouts, valve lockouts, plug lockouts, cable lockouts, hasps, lock boxes.

▪️Use one lock per person—no piggybacking.

▪️Legible tags: name, department, phone, date/time, reason.

▪️Group LOTO: use a lock box and hasp when many people are involved.

▪️Test for zero energy every time before starting work.

Don’ts ❌

▪️Don’t remove someone else’s lock (ever).

▪️Don’t rely on tags only if a lock can be used.

▪️Don’t assume “off” means safe—verify.

▪️Don’t leave stored energy unaddressed (springs, pressure, gravity).

Common Mistakes (and fixes)

▪️Missed energy source → Use the equipment-specific procedure; walk down the system.

▪️Shared keys → Each worker keeps their own key; use a group lock box for coordination.

▪️Unreadable tags → Use durable, weather-resistant tags; write clearly with permanent marker.

▪️No verification → Always try-start or meter-test after isolation.

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Quick Pocket Checklist 🧰

Notify → Shut → Isolate → Lock → Tag → Release → Verify → Work → Remove → Start-up → Notify.

👷Safety Culture Message

No lock, no tag = no work.

If anyone pressures you to “just get it done,” your answer is: “We do it locked out.”

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Call to Action

Save this post, share it with your team, and run a 5-minute LOTO talk today.

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