Overview of LOTO (LockOut TagOut)

LOTO (Lockout Tagout) is the physical restraints of all potentially dangerous energy sources that transmit power to a piece of equipment, machinery, or system. The application of a Warning Tag to the physical restraint device is also part of LOTO. This document shows the Authorized LOTO staff as well as the date. LOTO operations must be done on all equipment, machinery, or system Shut Downs before Authorized Personnel can perform repairs or service. An Energy Isolation Device is installed on the majority of equipment and machinery. These devices are often set to the off position in order to turn off the potentially harmful energy source. Padlocks can be used to secure physical restraints (Lock Out Devices) on the Energy Isolation Device.


  • Marine industries
  • aerospace
  • electronic
  • Automobile
  • Chemical industries
  • Digital Manufacturing operation
  • Digital Manufacturing operation

Why LOTO is important

LOTO is a significant safety technique that aids in the protection of workers. LOTO-identified equipment and machinery are capable of unexpected start-ups, which may result in the destructive discharge of hazardous energy. 10% of industrial incidents are related to lockout/tagout issues. And, because some service and troubleshooting work may require the power to be turned on, LOTO procedures may be the only protection a worker has. Ensuring safety and security of the employees at all times is amongst the greatest responsibilities of any employers.

  1. Protects the workers from the risk of hazards and accidents
    When lockout tagout is not handled seriously, incidents occur. Loto are life-saving devices that, when used properly and in accordance with the loto procedures, protect employees from the release of harmful enegies during machine or equipment service or maintenance.
  2. protects the equipment machine and workplace from damage and reduces downtime
    It is important that we live in a safe and accident-free workplace, which can only be accomplished if we strictly adhere to lockout tagout rules. It decreases incidents and improves machine, equipment, and workplace safety.
  3. Builds trust and confidence in the employees
    Employees feel empowered when they work in a risk-free environment. LOTO enables all employees to return home safely, work with confidence, and feel secure.
  4. Customer satisfaction
    Even customers will benefit from the LOTO program, though not as directly. When a facility has a serious accident or other similar event it can cause serious delays in production. Taking the necessary precautions to avoid accidents will assist to ensure that customers receive what they require in the best possible condition.

Key Procedure for LOTO

  1. Determine the procedure

Firstly, need to be identified the procedure correctly then, determine the right procedure for shutting down and restarting the procedure. This procedure should allow you to identify the piece of equipment you’re working on.

2. Notify affected employees

Make sure all your employees and contractors that may be affected should be notified before the maintenance is going to be performed. Inform them of the work schedule and the length of time the equipment will be unavailable. If the lack of equipment needs a change in work practises, ensure that they are aware of the steps to be done.

3. Isolation and shutdown equipment properly

The lockout tagout process you use should include a list of all energy sources that must be isolated. Describe the shutdown procedure in detail. The shutdown instructions should be clear to ensure everyone’s safety and to minimise the possibility of damage.

4. Turn off all primary energy sources.

Use the locks and tags which have been assigned to the concerned person only; no one else should remove them unless a direct supervisor is present in exceptional circumstances. In most cases, this will require approval. If more than one person is involved in the machine’s or equipment’s maintenance or service, each person must connect their own lock or tag to the energy isolating device.

5. Address all secondary source

Before releasing any primary energy sources, make sure the environment is clear, and consider hazards such as moving equipment that should be secured before operating.

6. Verify the lockout

After disconnected all major and secondary energy sources, try to restart the equipement to verify that the lockout was successful. Once the lockout has been verified, attach a lockout or tagout device to the equipment to ensure that it cannot be started without the device being removed.

7. Maintain loto during shift changes

During shift changes, the equipment must stay in lockout/tagout condition so that workers arriving at the site are aware that the equipment is out of use. If individual locks or tags are used, both the person who designated the lockout/tagout and the person who will be responsible for it during the next shift must be present when the locks or tags are transferred.

8. Bring the equipment back

When the mission is finished and all tools and other materials have been removed, the machine can be restarted. Again, the procedure should specify the particular steps to be taken, as well as the correct sequence.


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