This poster is the full LOTOTO procedure - it's how we make sure a machine has ZERO energy before anyone touches it.

 This poster is the full LOTOTO procedure - it's how we make sure a machine has ZERO energy before anyone touches it.

LOTO is Lockout / Tagout. This version adds TRYOUT and VERIFY, which is the modern best practice. It means: ISOLATE - PROTECT - WORK SAFELY.

Here is what each step means in practice:

Stage 1: Preparation - Steps 1 to 3

1. PREPARE FOR SHUTDOWN

This is planning. Before you touch anything:

Review the specific isolation procedure for that equipment

Identify all energy sources, not just electricity

Notify everyone affected that you will shut it down

2. SHUT DOWN THE EQUIPMENT

Turn off the machine using its normal stop button / normal procedure. Don't just pull the isolator yet. Let it stop properly.

3. ISOLATE ENERGY SOURCES

Now physically isolate every source. The poster lists 6 types:

Electrical - breakers, switches

Mechanical - flywheels, rotating parts

Hydraulic - oil pressure

Pneumatic - air pressure

Thermal - steam, hot surfaces

Chemical - chemical lines

Close valves, open breakers, block moving parts.

Stage 2: Secure It - Steps 4 to 6

4. APPLY LOCKS

Use approved lockout devices only, no wire or tape

Each person puts their OWN lock. If 3 people are working, 3 locks. This is non-negotiable.

This physically prevents anyone from re-energizing.

5. APPLY TAGS

The tag is the warning. It must be:

Clear, durable, visible

With your Name, Dept, and Date

It says "DO NOT OPERATE - This lock/tag may only be removed by:" 

Lock stops the hand, tag warns the mind.

6. RELEASE STORED ENERGY

Even after isolation, energy is still trapped inside.

Bleed off pressure from gauges / bleed valves

Discharge capacitors, release springs

Drain liquids, vent gas

You must check for any remaining / residual energy. Assume it's still live until you prove it isn't.

Stage 3: Prove It's Safe and Do The Work - Steps 7 to 9

This is why LOTOTO is safer than old LOTO.

7. TRYOUT

Try to start it. Press the start button / test run controls. Confirm:

Equipment does NOT operate

No movement, no noise, no pressure build-up

Then return controls to OFF. This proves your isolation actually worked.

8. VERIFY ISOLATION

This is the technical check with instruments. Use a multimeter, pressure gauge, etc.

Check for absence of energy

Test at the point where you will actually put your hands

This is your Zero Energy Verification.

9. PERFORM THE WORK

Only now you work.

Follow safe work procedure

Never remove another person's lock/tag

Keep the area barricaded and secured

Stage 4: Bring It Back Safely - Steps 10 to 12

10. REMOVE TOOLS & MATERIALS

Before you re-energize, inspect:

Remove all tools, rags, spare parts

Leave area clean and safe. Nothing left inside that can become a projectile or cause a short.

11. REMOVE LOCKS & TAGS

Only the person who put the lock can remove it

Verify work is 100% complete and everyone is clear of the machine

Remove in the correct order as per procedure

12. RESTORE TO NORMAL

Re-energize systems

Press START and return equipment to service

Monitor for proper operation, leaks, unusual noise, vibration

Bottom line of the poster says it all: LOCKOUT • TAGOUT • TRYOUT • VERIFY = NO ENERGY • NO ACCIDENTS. Safety is Everyone's Responsibility.

The two mistakes that cause most LOTOTO fatalities are: skipping Step 6 (stored energy) and skipping Steps 7 & 8 (tryout and verify). ✅🚧💯🦺🚦⚠️🚨🌡️🏗️🚥📝⛑️

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