The Top 5 Lockout Tagout Mistakes and How to Avoid Them
Posted by ZING Safety on Apr 19th 2023
Lockout/Tagout (LOTO) is a critical procedure to control hazardous energy—electrical, mechanical, hydraulic, pneumatic, thermal, or chemical. Despite its importance, programs often miss simple steps that keep people safe. Use this guide to tighten your process and reinforce training.
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Failing to Properly Identify All Energy Sources
Missing an energy source (electrical, hydraulic, pneumatic, mechanical, thermal, chemical) puts workers at risk.
Fix it: Use machine-specific energy control procedures that list every source and isolation point. Post diagrams at the point of use and verify during shift handoffs.
Not Following the Correct Sequence of Lockout Steps
Skipping steps or improvising order leads to gaps in isolation and verification.
Fix it: Standardize the sequence (notify → shutdown → isolate → apply lock/tag → release stored energy → verify zero energy → perform work → remove devices → restore). Train annually and after changes.
Failing to Remove All Stored Energy
Residual pressure, gravity, springs, and capacitors can re-energize unexpectedly.
Fix it: Bleed, vent, block, discharge, or mechanically restrain. Document methods by machine and require a try-start and meter test before work begins.
Not Properly Securing Lockout Devices
Loose, incorrect, or improvised devices can be bypassed or fall off under vibration.
Fix it: Standardize device types and sizes (breaker, valve, plug, cable); use hasps for group lockout; issue uniquely keyed padlocks; inspect stations weekly.
Failure to Conduct Regular LOTO Audits
Without audits, programs drift and shortcuts become normal.
Fix it: Schedule periodic inspections (at least annually per OSHA) by trained personnel. Sample jobs, interview workers, and correct discrepancies with retraining.
LOTO Quick-Hit Checklist
- Machine-specific procedures list all energy sources and isolation points.
- Standard sequence is posted and used at the point of work.
- Stored energy release/retention steps are documented and verified.
- Devices fit correctly; padlocks are uniquely keyed; hasps used for groups.
- Periodic audits completed; gaps corrected; training records updated.
Outfit Your LOTO Program
Lockout Devices
Valve, breaker, plug & cable devices for every energy type.
Safety Padlocks
Durable, non-conductive, uniquely keyed; engraving available.
Tags & Hasps
High-visibility tags, steel/nylon hasps, and group lock boxes.
Stations & Kits
Wall stations, shadow boards, portable kits for readiness.