Top 7 Steps To Create an Effective Lockout/Tagout Program

By October 20, 2021All Solutions, Panduit, Solutions

Just shutting down or disconnecting equipment is not enough…Lockout/ Tagout keeps employees safe by making it inoperable. Comply with OSHA Regulations and LOCK IT OUT!

Before repairs, servicing, maintenance, or set-up of machines and equipment can begin, prevent the unexpected — the accidental start-up!

Procedures, devices, and personnel must be set in place to prevent the serious injury or death that could occur when someone thinks something is safely off. To ensure machines and equipment remain inoperable means establishing a “program consisting of energy control procedures, employee training, and periodic inspections…” as described in the OSHA standard. The standard also identifies products used for achieving these goals, such as lockout and tagout devices.

Highlighted here are seven steps to creating an effective Lockout/Tagout program.

1. Be Aware of the Lockout Regulations

Become familiar with the federal regulations known as The Control of Hazardous Energy (Lockout/Tagout).

2. Develop List of Machinery & Equipment

Survey your facility for all machinery and equipment that have the potential for requiring lockout.

3. Identify & Mark Energy Sources & Lockout Points

Locate and document start-up areas of energy sources, such as Mechanical, Electrical, Hydraulic, Thermal, Pressure, Process Control, Stored Energy (gravity, springs).

4. Determine the Lockout Controls

Identify and document the necessary devices that isolate and lockout energy sources, and secure them for on-site use. Standardize the devices for various functions for proper identification.


5. Set up Lockout Training & Procedure Program

Develop, standardize, and document the lockout process for each energy source. Identify employees’ level of involvement in the program – those that are made aware, affected, and to perform the lockout procedures. Accomplish this through comprehensive training programs and certifications.

6. Implement the Lockout Program

Initiate and enact the Lockout/Tagout program in accordance with the training procedures. Post reminders and have the necessary Lockout/Tagout devices readily available.

7. Review Lockout Program

Identify and document changes to existing procedures and new energy sources that require lockout. Make corrections, changes, and additions to the program. Conduct periodic reviews of lockout procedures (required at least annually) to ensure they are up to date and requirements are being met.

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