Top 5 Lockout/Tagout Mistakes

Lockout/Tagout (LOTO) remains one of OSHA’s top ten most-cited violations. Even companies with strong programs can make critical mistakes—often due to complacency, incomplete training, or overlooked steps. This guide explores five of the most common Lockout/Tagout errors and how to prevent them.

1. Loose Clothing

Loose or tattered clothing poses serious hazards near moving machinery. According to a BLS study, over 20% of machine-related fatalities involved clothing caught in moving parts.

• Prohibit loose-fitting clothes or dangling accessories near machinery.
• Include clothing checks in pre-work safety inspections.
• Adopt standardized uniforms for high-risk operations.

Even well-developed lockout programs fail if workers ignore basic physical hazards like loose clothing.

2. Reaching Through or Stepping Over Equipment

Workers who bypass guards or enter danger zones without locking out equipment put themselves at risk. LOTO applies whenever any part of the body enters a hazardous area—even if “just for a second.”

• Require full lockout for guard removal or proximity to moving parts.
• Post signage at pinch points and high-risk zones.
• Retrain employees who misunderstand “authorized” vs. “affected” roles.

3. Poor Jam Prevention

Ten percent of LOTO fatalities happen during jam clearing. Preventing jams eliminates one of the most dangerous maintenance activities.

• Design systems with remote lubrication and cleaning ports.
• Install extended oiler tubes to reduce close contact with moving parts.
• Always lock out before removing obstructions.

4. Failure to Drain Residual Energy

Machines may still contain stored energy even after being locked out. Always drain or release residual energy before maintenance begins.

• Electrical: Discharge capacitors fully before work begins.
• Hydraulic/Pneumatic: Use pressure relief valves to bleed lines.
• Mechanical: Release or block compressed springs.
• Gravitational: Lower any raised parts to their resting position.

Always test to confirm energy has been released before proceeding.

5. Failure to Retrain or Update Procedures

Lockout programs must evolve with your workplace. Regular audits and retraining ensure that procedures stay current and effective.

• Conduct annual audits of all lockout procedures.
• Retrain staff after new equipment installation or job changes.
• Encourage worker feedback to improve procedures and device selection.

Compliance is not a one-time effort—it’s an ongoing process requiring vigilance and communication.

Lockout Registers help you organize and document your entire LOTO program.

Conclusion

LOTO compliance isn’t static—it’s a living system that requires regular attention, training, and review. A strong safety culture encourages communication and continuous improvement. If you have questions about Lockout/Tagout procedures or need product support, contact Zing Green Products.