What Are LOTO Procedures?

You know that machinery doesn't have to be running to be dangerous. Even after you turn equipment off, hazardous energy can still linger stored in compressed air, spring tension, heated surfaces, or electrical charge. That’s why OSHA requires every facility to implement lockout/tagout (LOTO) procedures.

LOTO procedures are about consistency as much as safety. They give your maintenance team a clear, repeatable process for safely disabling and servicing equipment, no matter who’s on shift or what asset’s being worked on.

Key takeaways

• LOTO procedures are essential for preventing serious workplace injuries.
• Each step must be followed precisely to control hazardous energy.
• Identifying and isolating all energy sources is critical for full equipment shutdown.
• Regular training and audits ensure continued compliance and safety.

How LOTO procedures protect your operation

LOTO procedures (short for lockout/tagout) are machine-specific instructions that outline how to safely control hazardous energy before performing maintenance or servicing. Their purpose is to protect anyone working on or near machines or equipment from the unexpected release of stored or residual energy.

A complete LOTO procedure includes steps to:

• Identify and isolate all energy sources
• Release any stored or residual energy
• Apply lockout and tagout devices to secure those energy sources
• Verify isolation before maintenance begins

According to OSHA, every LOTO procedure must use both a lock and a tag, which serve different but equally important purposes:

• Locks physically prevent the re-energization of a machine. By attaching them to energy isolating devices (such as circuit breakers, line valves, or plug disconnects), you ensure that equipment stays powered off until the work is complete.
• Tags are prominent warning devices that clearly communicate who applied the lock, when it was applied, and why. They help protect your workers from accidental restarts and must be durable and legible.

It might seem like onerous red tape, but LOTO procedures are critical for keeping your team members safe. Unfortunately, LOTO failures are far too common, and the consequences can be severe.

In 2024 alone, OSHA cited more than 2,400 violations of its lockout/tagout standard (§1910.147), according to a report by EHS Daily Advisor. These violations were tied to serious injuries, amputations, and even fatalities. In one case, a Texas manufacturer was fined over $250,000 after an employee suffered an injury that resulted in a partial arm amputation while trying to clear debris from machinery. Investigators found the company hadn’t implemented proper lockout/tagout procedures or trained employees on how to follow them.

In other words: A strong LOTO program doesn’t just protect your people. It protects your business, your uptime, and your bottom line.

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Why are LOTO procedures so important?

It’s not enough to power down a machine. Electrical connections can still hold charge. Mechanical energy can be trapped in springs, gears, or belts. Thermal energy can linger in heated tanks or lines. If you don’t have a process to isolate and release these energy sources, you’re putting workers at risk.

LOTO procedures give your maintenance team a safe, repeatable way to:

• Shut down machines using standard shutdown procedures
• Prevent unexpected energization
• Safely release potentially hazardous stored energy
• Communicate clearly with other employees about ongoing maintenance
• Restore machines to their safe position when work is complete

They’re also essential for documenting your occupational safety practices, especially during audits or regulatory inspections.

Regulations that govern LOTO procedures

LOTO procedures aren’t optional; they’re a required part of OSHA’s Control of Hazardous Energy standard (29 CFR 1910.147). This regulation lays out how companies must develop, train employees on, and enforce hazardous energy control procedures across every piece of equipment where maintenance or servicing might occur.

These procedures must include:

• A clear explanation of how to shut down and isolate energy sources
• The types and locations of energy isolating devices
• Instructions for applying lockout devices or tagout systems
• Steps to verify energy isolation before work begins
• Procedures for restoring the machine to service

In short: If you’re asking employees to perform maintenance, servicing, or maintenance activities, you need specific procedures in place and you need to prove that your team is trained on them.

LOTO procedure step-by-step guide

So, what does a complete LOTO procedure actually look like? Here’s a breakdown of the key steps involved.

1. Preparation

Before touching the equipment, the authorized employee must identify:

• The exact machine or equipment being serviced
• All associated hazardous energy sources (electrical, hydraulic, pneumatic, thermal, chemical, etc.)
• The energy control devices (circuit breakers, line valves, disconnects) needed to isolate each source

They also need to review the machine-specific energy control procedure, a written set of instructions that details each step required to perform a safe lockout. This step helps prevent mistakes like overlooking a secondary energy source or underestimating residual or stored energy.

If your team skips this part, you're not just risking injuries; you're also likely out of compliance with OSHA.

2. Notification

Next, the authorized employee must alert all affected employees anyone working near or relying on the machine. Let them know:

• Which equipment is being locked out
• Why the lockout is taking place
• When it will begin and how long it’s expected to last

Clear communication prevents confusion and reduces the chance that someone tries to restart the system mid-maintenance.

3. Shutdown

Now it’s time to turn off the equipment using its normal production operations. That could mean flipping a switch, powering down a control panel, or stopping a process line.

It’s important not to rely solely on emergency stops, they don’t isolate energy, and they don’t guarantee safety. This step ensures the machine is in a stable condition before moving forward.

4. Isolation

Once powered down, isolate the equipment from all energy sources using the appropriate energy isolating devices. These might include:

• Line valves (hydraulic, pneumatic, steam)
• Circuit breakers or disconnect switches (electrical)
• Plugs or cord disconnects for plug-connected electric equipment

Miss one source during your energy control procedure, and you're putting workers at risk.

5. Application of lockout/tagout devices

After the energy has been isolated, it’s time to apply lockout/tagout devices.

• Attach a lock to each energy isolating device.
• Apply a tag with the name of the authorized employee who performed the lockout, the date, and a reason for the shutdown.
• Make sure only that employee can remove the lock (that’s what OSHA refers to as exclusive control).

Tags serve as a prominent warning device to everyone else. Even if someone has access to the equipment, the lockout/tagout device should stop them in their tracks.

6. Release of stored energy

Just because the machine is off doesn’t mean it’s safe. Many machines retain stored or residual energy that must be released or restrained before maintenance begins.

Depending on the system, this might include:

• Bleeding off hydraulic or pneumatic pressure
• Grounding capacitors
• Draining hot fluids or chemicals
• Releasing tension from springs
• Bracing suspended parts

Each of these steps prevents sudden movement, chemical exposure, or heat-related injury. It's one of the most overlooked but critical phases of LOTO safety.

7. Verification of isolation

Once lockout devices are applied and stored energy is released, you’re almost ready to begin work, but not quite yet. The authorized employee must attempt to start the equipment using the standard controls (start button, valve, etc.). Nothing should happen. If it does, stop and reassess.

This verification confirms that the machine is truly de-energized and safe.

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8. Performing the work

Now the maintenance work can begin. Whether it’s preventive care, repairs, inspections, or tool changes, your team can safely perform tasks knowing the system is fully isolated and controlled. Make sure the employee performing the work continues to monitor for any changes or conditions that could reintroduce energy.

Also worth noting: If the job requires multiple technicians, you should institute a group lockout procedure and lockbox system to ensure every person has control over their own safety.

9. Returning to service

Once the task is complete, you must bring the machine back into service carefully.

• Remove all tools and protective devices.
• Confirm all components are reinstalled correctly.
• Verify that other employees are clear of the area.
• Remove lockout/tagout devices. Only the authorized person who applied the lock can do this, unless specific exceptions are documented in your lockout program.
• Re-energize the machine and return it to normal production operations.

At this point, you should notify affected workers that the equipment is back online and ready for use.

Check out the Maintainx LOTO procedure template for a deeper dive.

Build safer habits with better LOTO systems

Good LOTO procedures are more than just a box to check. They help you create a safer, more predictable environment for everyone on the floor. And when you follow them correctly, they help you:

• Stay compliant with OSHA
• Protect workers from serious injury
• Minimize unplanned downtime
• Maintain trust with your maintenance and operations teams

To make all of this easier, MaintainX gives you a centralized, digital home for your LOTO procedures. Assign, track, and audit your energy control program from anywhere on any device.

‍See how MaintainX helps streamline LOTO.