Mastering Lockout/Tagout: The 5 Most Frequently Violated Steps

Frequently Asked Questions

What are the most commonly violated lockout/tagout steps?

The post identifies five common failure points: incomplete equipment shutdown, missing or incorrect energy isolation points, failure to control stored or residual energy, skipping verification of isolation, and unsafe release from lockout and restart.

Why is verification such a critical step in lockout/tagout?

The post says lockout/tagout is not complete until the authorized employee confirms the equipment has been effectively isolated and rendered safe. Verification should be an active field step before work begins, not just a paperwork sign-off.

What counts as stored or residual energy in a LOTO procedure?

Examples in the post include pressure in pneumatic or hydraulic lines, elevated machine parts, spring tension, capacitors, hot surfaces, and pressure or product left in vessels and piping. The procedure should spell out exactly how each source is released, restrained, blocked, or allowed to dissipate.

How can EHS managers improve lockout/tagout procedures in the field?

The post recommends making procedures equipment-specific, verifying isolation points in the field, improving labeling, and updating procedures after modifications or projects. It also suggests auditing high-risk equipment and checking whether workers can follow the process under real production conditions.

What should happen before equipment is restarted after lockout/tagout?

The work area should be inspected, employees should be confirmed clear and safely positioned, and affected employees should be notified before restart. The post also says locks and tags should be removed by the authorized person who applied them, following the employer’s procedure.