Sample lockout tagout procedure: a step-by-step template you can actually use

Last updated 2026-07-09

What is a lockout tagout procedure and why does OSHA require one?

A lockout tagout procedure is a written, equipment-specific set of steps workers follow to shut down a machine, isolate its energy sources, and confirm it can't restart before anyone does maintenance, cleaning, or repair on it. The goal is simple. Keep the machine from starting while someone's hands are inside it.

OSHA's rule is 29 CFR 1910.147, the Control of Hazardous Energy standard, usually called the LOTO standard. ^[1] It applies to general industry employers and covers any equipment that could release electrical, hydraulic, pneumatic, chemical, thermal, or gravitational energy. Construction and maritime have their own rules, though the concepts line up closely.

The standard tells employers to develop, document, and use energy control procedures for each piece of equipment where an unexpected startup could hurt a worker. ^[1] That phrase "each piece of equipment" matters. A generic procedure covering all your machines does not satisfy OSHA. You need an equipment-specific procedure for each machine unless it meets a narrow exception (see the FAQ for that one).

1910.147 lands among the top five most-cited violations in general industry year after year. OSHA issued more than 2,500 LOTO-related citations in fiscal year 2023. ^[2] OSHA estimates that following the standard could prevent roughly 120 fatalities and 50,000 injuries a year across the United States. ^[3] Those numbers make the case on their own.

What are the six steps of a lockout tagout procedure?

The six steps below come straight from 29 CFR 1910.147(d), OSHA's sequence for energy control. Every written procedure you build should map to these steps, in this order.

Step 1: Notify affected employees. Before you touch anything mechanical, tell everyone who works near or with the equipment that it's going down and why. Affected employees are the workers who run the equipment but won't do the actual service work. They need to know a LOTO is happening so nobody tries to start the machine.

Step 2: Identify energy sources and shut down the equipment. Read your written procedure and list every energy source connected to the machine: electrical panels, pneumatic lines, hydraulic circuits, gravity-fed systems, steam lines, springs under tension. Then follow the normal stopping procedure to power the machine down. This isn't the lockout step yet. You're just turning it off.

Step 3: Isolate every energy source. Operate each energy-isolating device, which could be a disconnect switch, a circuit breaker, a valve, or a blank flange, to physically cut the machine off from its energy sources. ^[1] All of them, more than the obvious electrical one. A press that runs on electricity and compressed air needs both isolated.

Step 4: Apply lockout and tagout devices. Each authorized employee doing the work puts their own personal lock on each energy-isolating device. The tag goes on the lock or the device to identify who placed it and why. Multiple workers means multiple locks. Nobody removes someone else's lock. Ever.

Step 5: Release or restrain stored energy. This step trips up a lot of people. Cutting power does not drain stored energy. You bleed hydraulic lines, discharge capacitors, block suspended parts against gravity, release spring tension, drain or vent pressurized systems, and let heated parts cool. ^[1] Every bit of residual energy has to go somewhere.

Step 6: Verify the equipment is de-energized. Before anyone touches the machine's guts, prove isolation is complete. Try the normal start controls (push the start button, turn the switch) to confirm the machine won't run. Use a meter to check that electrical circuits are dead. Read the pressure gauges and confirm zero. Work begins only after verification.

OSHA states in 1910.147(d)(6) that the authorized employee "shall verify that isolation and de-energization of the machine or equipment have been accomplished" before any servicing begins. ^[1] That verification step is not optional, and it's one of the most frequently skipped. Inspectors know it, and they look for it.

What should a written lockout tagout procedure include?

OSHA's 29 CFR 1910.147 Appendix C is a non-mandatory example, but it's the clearest picture of what OSHA expects in a documented procedure. ^[1] Your written procedure for each machine should contain at minimum:

• Equipment identification: machine name, model number, location on your floor, and a photo or diagram if the machine is complex.
• Steps to shut down: the normal operating sequence to stop the machine safely before isolation begins.
• Energy sources listed individually: each source by type (electrical, pneumatic, hydraulic, etc.), its location, magnitude (voltage, PSI, BTU), and the isolating device that controls it.
• Steps to isolate: which disconnect, valve, or other device to operate, and in what order.
• Steps to apply LOTO devices: where each lock goes and what type of device is required (hasp, lockout clamp, valve lockout, etc.).
• Steps to release stored energy: specific methods for each type of residual energy on this machine.
• Verification method: how the authorized employee confirms a zero energy state before work starts.
• Steps to restore energy after work: the reverse sequence, including checking that tools and people are clear, removing locks, notifying affected employees, and returning the machine to service.

The procedure should also name or describe who is authorized to perform the lockout (authorized employees, as distinct from affected employees who just run the machine).

For a lockout tagout program document that covers your whole facility, you'll also need a written energy control program that explains how training happens, how procedures get written and reviewed, and how the annual inspections are done. The written procedure for each machine is one piece of that larger program.

Sample lockout tagout procedure template (fill-in format)

Below is a template that mirrors the structure OSHA describes in 29 CFR 1910.147 Appendix C. Fill in the bracketed fields for each piece of equipment.

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ENERGY CONTROL PROCEDURE

Equipment name: [e.g., Conveyor Belt Drive Unit] Equipment ID / asset number: [e.g., CBU-04] Department / location: [e.g., Assembly Line 3, North Wall] Date written: [MM/DD/YYYY] Procedure author: [Name, title] Review date: [MM/DD/YYYY]

ENERGY SOURCES

Energy Type	Source Location	Magnitude	Isolating Device	Device Location
Electrical	Main panel, breaker 14	480V, 3-phase	Lockable disconnect switch	Left side of machine
Pneumatic	Air supply line	90 PSI	Ball valve, 1/2" red handle	Below control panel
Hydraulic	Hydraulic power unit	1,500 PSI	Manual shutoff valve	HPU cabinet, rear
Gravity	Roller carriage, upper position	Weight: 200 lbs	Blocking stand (item #CS-7)	Maintenance cage shelf B

STEP-BY-STEP PROCEDURE

1. Notify all affected employees that [equipment name] will be shut down for maintenance. 2. Press the red STOP button on the operator panel to complete the normal stop cycle. 3. Turn the lockable disconnect switch on the left side of the machine to the OFF position. 4. Close the pneumatic ball valve below the control panel. 5. Close the hydraulic shutoff valve in the HPU cabinet. 6. Apply your personal lock and tag to the disconnect switch hasp. Apply your personal lock and tag to the pneumatic valve lockout. Apply your personal lock and tag to the hydraulic valve lockout. 7. Press the bleed button on the pneumatic manifold to release air pressure. Confirm gauge reads 0 PSI. 8. Open the hydraulic return line bleed valve to release hydraulic pressure. Confirm gauge reads 0 PSI. 9. If the roller carriage is in the raised position, insert blocking stand CS-7 beneath it before working in the travel zone. 10. Attempt to start the equipment by pressing the green START button. Confirm no motion occurs. 11. Use a calibrated voltage meter to verify 0 volts at the machine terminals. 12. Work may now begin.

RESTORE TO SERVICE

1. Remove all tools and materials from the machine. 2. Confirm all workers are clear. 3. Remove blocking stand CS-7 if used. 4. Each authorized employee removes their own lock and tag from each device. 5. Close the hydraulic and pneumatic lines. 6. Turn the disconnect switch to ON. 7. Notify affected employees that lockout is complete and equipment is being returned to service. 8. Test-run the equipment per normal startup procedure.

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This template is a starting point. A conveyor is simpler than an injection molding press or a CNC machining center. Complex equipment with multiple energy sources, multiple modes of operation, or tricky stored energy may need diagrams, photos, or extra steps. If you have a lot of machines to document, a tool like SafetyFolio can generate equipment-specific LOTO procedures in a fraction of the time it takes to build them from scratch.

What is the difference between lockout and tagout?

Lockout and tagout are two different ways to control hazardous energy, and they are not equal. One physically stops the machine. The other just warns you.

Lockout means putting a physical lock on an energy-isolating device so the device can't be operated. The lock stops the switch from being flipped, the valve from being opened, the breaker from being reset. Only the person who applied the lock can remove it.

Tagout means putting a tag on an energy-isolating device when a lock can't go on it. The tag is a warning device. It does nothing to physically stop operation. It tells other workers not to touch the device because someone's working on the equipment.

OSHA's position is clear: lockout wins. If an energy-isolating device is lockable (it has a hasp or mechanism that accepts a lock), you use a lock. Tagout alone is only allowed when the equipment can't be locked out. ^[1] Even then, the employer has to show that tagout gives the same protection as lockout, which takes extra measures like removing a valve handle or blocking a breaker.

Almost all modern equipment can be locked out. If you're running a tagout-only program on machines that have lockable disconnects, you have a citation waiting to happen.

So buy padlocks, hasps, and lockout stations. A basic personal safety lock costs $5 to $15. A serious LOTO violation can run up to $16,131 per violation, and a willful violation up to $161,323, under current OSHA penalty levels. ^[4] The math isn't close.

Who is an authorized employee vs. an affected employee under OSHA?

OSHA's 1910.147 draws a firm line between two groups, and mixing them up is a common mistake.

An authorized employee performs the lockout or tagout. They apply the locks, follow the written procedure, do the service or maintenance work, and remove the locks when they're done. They need training on the specific energy control procedure for each machine they work on. ^[1]

An affected employee runs the equipment in the normal course of their job or works in an area where energy control happens. They need to know a lockout is on, that they shouldn't try to start the equipment, and why. Their training requirement is lighter but still required under 1910.147(c)(7). ^[1]

A third category, other employees, covers anyone else who works in areas where energy control procedures are used. They need basic awareness training: what the program is, what a lock and tag mean, and that they never remove a lock or tag that isn't theirs. ^[1]

One worker can be both authorized and affected depending on the situation. A maintenance tech who does the lockout is authorized. When a different tech locks out a nearby machine, that first tech becomes an affected employee. The categories are role-based, not person-based.

Training has to be documented. Keep records of who was trained, what on, and when. ^[1] If an inspector asks for training records and you don't have them, OSHA can treat it as if the training never happened.

How do you handle group lockout when multiple workers are on the same job?

Group lockout shows up whenever multiple techs work on one machine or system. OSHA's 1910.147(f)(3) covers it, and the rule is plain: each authorized employee gets the same protection they'd have with an individual lockout. ^[1]

The standard tool is a group lockout box or hasp. Here's how it works.

One primary authorized employee, often the lead technician, locks out all the energy-isolating devices. That lead tech then puts a single lock on a group lockout box or uses a multi-lock hasp. Every other authorized employee on the job adds their own personal lock to that same box or hasp. The box or hasp can't be opened, and the equipment can't be re-energized, until every worker has pulled their individual lock.

When a job crosses a shift change, the procedure has to keep protection unbroken. The off-going worker can't just yank their lock at quitting time if the work is still live. Both the outgoing and incoming authorized employees need to be present for the handoff so there's no gap. OSHA's 1910.147(f)(4) requires a specific procedure for shift changes. ^[1]

If your facility runs complex maintenance with contractors or multiple departments hitting one system at once, you may also need a procedure for coordinating between employers under 1910.147(f)(2).

For workers taking general osha training courses, LOTO usually shows up as a module inside the wider curriculum. An osha 30 course covers LOTO concepts at a supervisory level, but facility-specific training on your actual procedures still has to happen separately.

What are the most common LOTO violations OSHA cites?

The most frequently cited LOTO problems fall into a handful of buckets, based on OSHA's citation data and inspection focus. ^[2] Here's what inspectors zero in on.

Violation Type	CFR Reference	What Inspectors Look For
No written energy control procedures	1910.147(c)(4)	No documented procedure for specific equipment
Generic procedures instead of machine-specific	1910.147(c)(4)(i)	One procedure applied to all machines
No annual periodic inspection	1910.147(c)(6)	No records of annual review and certification
Inadequate training documentation	1910.147(c)(7)	No records of who was trained or when
Tagout used where lockout is feasible	1910.147(c)(1)	Locks not used on lockable devices
Stored energy not addressed	1910.147(d)(5)	No bleed, block, or discharge steps in procedure
Locks not applied by each worker	1910.147(f)(3)	Shared locks or one lock for a crew

The annual periodic inspection is the one people miss constantly. At least once a year, a qualified person has to review each energy control procedure to confirm it's adequate and that the employees using it are following it correctly. ^[1] That review has to be certified in writing, with the date, the machine covered, the names of the employees involved, and the name of the person who did the review.

Plenty of small businesses write decent procedures and never look at them again. OSHA will ask for the last three years of inspection records. If you can't produce them, that's a separate citation stacked on top of whatever else they find.

Does every machine need its own lockout tagout procedure?

Generally, yes. OSHA requires a written procedure for each machine or piece of equipment where hazardous energy could be released. There's one limited exception, under 1910.147(c)(4)(i).

A written procedure is not required only if ALL of the following are true for a specific machine:

1. The machine has a single energy source that can be fully de-energized and isolated by one switch or breaker. 2. That single energy source can be locked out. 3. Locking out the single source completely de-energizes and de-activates the machine. 4. The machine is isolated and de-energized from that single source. 5. There's no potential for stored or residual energy after isolation. 6. The machine can be locked out with a single lock.

A basic bench grinder plugged into a standard outlet, with no stored energy, no complex controls, and a plug you can just pull, might qualify. An injection molding machine with hydraulics, heaters, and pneumatics absolutely does not.

OSHA issued a letter of interpretation on this exception making clear it's narrow and that most industrial equipment won't qualify. ^[5] When in doubt, write the procedure. Writing one costs you time. Skipping one costs you a citation, or worse, a worker.

Build a good filing system for your machine-specific procedures early. Index them by equipment number or location so any maintenance tech can find the right procedure before starting work. Some facilities laminate the procedure and mount it right on or near the machine.

How does LOTO apply to electrical work specifically?

Electrical work carries an extra layer under NFPA 70E and OSHA's electrical safety standards at 29 CFR 1910.303 through 1910.399, but 1910.147 still applies to any electrical energy source feeding a machine. ^[6]

The practical difference: for electrical maintenance on a machine, you use 1910.147 to lock out the disconnect or breaker feeding it. For work on electrical systems themselves, like panel work or wiring, OSHA's electrical standards and NFPA 70E come in, and an electrically safe work condition (ESWC) is required.

A common mistake is thinking flipping a breaker off is enough. Under 1910.147, the breaker has to be locked in the off position, more than switched off. Breaker lockout devices (plastic clips that slip over a breaker handle and accept a padlock) cost a few dollars each and sell at any electrical supply house.

Machines with control circuits need care. Locking out the main power disconnect does not necessarily kill control circuit components if they draw from a different source. Your written procedure has to address each source on its own.

Electrical LOTO also crosses paths with hazard communication when you work on equipment that handles hazardous chemicals. Stored chemical energy in pressurized tanks or heated reactors is a form of hazardous energy your LOTO procedure has to account for.

What equipment and supplies do you need for a LOTO program?

The hardware side of LOTO is one place you genuinely don't need to spend much money. The basics:

Personal padlocks: Each authorized employee needs their own lock, with a key only they control. A standard keyed-different safety padlock runs $5 to $20. Some facilities use keyed-alike sets within a group (each employee's lock matches only their key), but keyed-different is the safest approach.

Hasps: A hasp is a multi-hole device that lets several workers lock out one energy-isolating device. A basic 6-hole hasp costs $3 to $10. Buy several.

Lockout tags: These go on or with every lock. They carry the worker's name, the date, and a warning not to operate the equipment. Pre-printed tags that meet OSHA's requirements (durable, standardized, clearly worded) come in packs for under $20.

Equipment-specific lockout devices: Some energy-isolating devices need special hardware. Pneumatic valve lockouts, circuit breaker lockout clips, plug lockout covers, gate valve lockouts, and cable lockouts are all common. A basic starter kit runs $50 to $150 depending on your mix of equipment.

Lockout station: A mounted board or box where all the above hardware lives, visible at the point of use. Not required by OSHA, but inspectors and workers both like a dedicated spot. These range from $30 for a basic wall board to several hundred dollars for full cabinet systems.

For a small shop with a handful of machines, total hardware costs often land under $500. The written procedures and training documentation are the harder, slower part.

How do you train employees on lockout tagout procedures?

OSHA's training requirement under 1910.147(c)(7) is specific: training has to make sure authorized employees understand the purpose of the energy control program, have the knowledge and skills to apply it, and can safely perform lockout or tagout. ^[1] Affected employees have to understand the purpose and use of the procedure and know to stay clear of machines that are locked out.

Training has to cover the specific procedures for each machine the employee will work on, more than generic LOTO concepts. A maintenance tech who'll lock out your conveyor system, your compressor, and your hydraulic press needs hands-on training on all three and their specific procedures.

Retraining is required when there's reason to believe an employee doesn't understand or isn't following procedures, when job assignments change, when new equipment goes in, or when procedures change. ^[1] The standard sets no fixed annual retraining requirement, but the annual periodic inspection often surfaces deficiencies that trigger retraining.

Training documentation needs at minimum the employee's name, the date of training, and what was covered. OSHA doesn't dictate a form, but signed training records are the practical standard. If an employee is injured and you claim they were trained, you'll need proof.

For supervisors and safety managers who want a wider grounding in OSHA rules, an osha 30 training course covers energy control as part of the overall curriculum. That's a solid foundation, but it doesn't replace facility-specific LOTO training on your actual equipment.

How do you write LOTO procedures efficiently if you have a lot of equipment?

Writing equipment-specific LOTO procedures is the part of compliance that eats the most time. A single well-documented procedure for a complex machine can take a couple of hours from scratch: walking down the machine, identifying energy sources, testing isolation points, writing the steps, having another tech check it for accuracy.

For a facility with 20 or 30 machines, that's a real project. A few things make it manageable.

Group similar machines. If you have five identical punch presses from the same manufacturer, write one detailed procedure, verify it works on each machine, and note any unit-specific differences. Five procedures might shrink to two.

Use a consistent template. The one earlier in this article is a good starting point. Consistency makes new procedures faster to write and easier for workers to recognize.

Do machine walkthroughs with your most experienced maintenance tech. They know where the weird energy sources hide on a machine that the operator panel never shows. Writing a procedure without that knowledge is how you end up missing a stored-energy hazard.

If you need to build an entire written energy control program from scratch, along with the individual machine procedures, SafetyFolio's safety program generator can build the framework in minutes. That leaves you to fill in the machine-specific details instead of building the document structure from zero.

Keep procedures at the point of use. A binder in the safety manager's office does nothing for the workers who need them. Digital copies on a tablet mounted near the machine, laminated copies attached to the equipment, or QR codes linking to current versions all work.

Frequently asked questions

What is the OSHA standard for lockout tagout?

The standard is 29 CFR 1910.147, titled 'Control of Hazardous Energy (Lockout/Tagout).' It applies to general industry and covers any equipment where unexpected energization or release of stored energy could harm a worker during servicing or maintenance. Construction and maritime have separate OSHA standards covering similar energy control requirements.

Do you need a separate lockout tagout procedure for every machine?

Yes, in most cases. OSHA requires equipment-specific written procedures for each machine with multiple energy sources or where stored energy is present. A narrow exception under 1910.147(c)(4)(i) applies to machines with a single lockable energy source and no stored energy, but most industrial equipment does not qualify. When in doubt, write the procedure.

What is the difference between an authorized employee and an affected employee?

An authorized employee performs the lockout or tagout and does the service work. An affected employee operates the equipment normally and works near it but does not perform the lockout. Both groups require training under 1910.147, but the content differs. Authorized employees need detailed, hands-on training on specific energy control procedures.

Can you use a tag instead of a lock?

Only when the energy-isolating device cannot be locked out. OSHA's 1910.147 requires lockout whenever the device can accept a lock. Tags alone do not physically prevent re-energization. Using tagout on a lockable device is a violation. Tagout-only programs also require additional protective measures to match the level of protection a lock provides.

How often do lockout tagout procedures need to be reviewed?

OSHA requires at least one periodic inspection per year for each energy control procedure under 1910.147(c)(6). The inspection must be certified in writing with the date, the equipment covered, the employees involved, and the name of the person conducting the review. Keeping three years of records is a reasonable target for when OSHA inspects.

What is stored energy and how do you address it in a LOTO procedure?

Stored energy is energy left in a machine after power is turned off. Examples include compressed air in pneumatic lines, hydraulic pressure in cylinders, electrical charge in capacitors, springs under tension, raised loads held by gravity, and heat in heated components. Your written procedure must include specific steps to release, block, or restrain each type of stored energy before work begins.

How does group lockout work when multiple workers are on the same job?

Under 1910.147(f)(3), each authorized employee in a group must apply their own personal lock. Typically the lead tech locks out all energy-isolating devices, then applies a lock to a group lockout hasp or box. Every other worker adds their own lock. The machine cannot be re-energized until all workers have removed their individual locks.

What happens during a shift change if a lockout is still in progress?

OSHA 1910.147(f)(4) requires a specific procedure for shift or personnel changes so protection continues without interruption. The outgoing and incoming authorized employees should both be present for the transfer. The incoming worker applies their lock before the outgoing worker removes theirs, so the energy-isolating devices are never unprotected during the handoff.

What are OSHA penalties for lockout tagout violations?

As of 2024, OSHA serious violations, where LOTO failures are typically classified, carry penalties up to $16,131 per violation. Willful or repeated violations can reach $161,323 per violation. Employers with multiple machines lacking written procedures or with no training documentation can face multiple citations from a single inspection.

Does LOTO apply to contractors working on my equipment?

Yes. Under 1910.147(f)(2), when outside contractors perform servicing or maintenance, the host employer and contractor must inform each other of their respective energy control procedures and coordinate so both sets of employees are protected. The host employer's procedures for the specific equipment should be shared with the contractor before work begins.

Are there industries or equipment types specifically exempted from 1910.147?

Some activities are exempt, including normal production operations using machine guarding, minor tool changes during production if protected by alternative methods, cord-and-plug connected equipment where the plug is under the control of the worker doing the service, and hot tap operations on pressurized pipelines under specific conditions. The exemptions are narrow. Review 1910.147(a)(2) carefully before relying on any of them.

How do I write a lockout tagout procedure for a machine I'm not familiar with?

Start with the manufacturer's manual, which often lists energy sources and recommended shutdown procedures. Then walk the machine with your most experienced maintenance tech and trace every energy input, including pneumatic, hydraulic, electrical, and thermal. Document what you find, draft the procedure, and have the tech verify each step is accurate before it goes into use.

What records do I need to keep for my LOTO program?

You need written energy control procedures for each covered machine, documentation of annual periodic inspections of each procedure, and training records for all authorized and affected employees. OSHA does not specify a retention period for most of these records, but keeping at least three years of inspection and training records is standard practice and covers most inspection lookback windows.

What is a lockout station and do I need one?

A lockout station is a wall-mounted board or cabinet where LOTO hardware (locks, hasps, tags, valve lockouts, etc.) is stored and readily accessible. OSHA does not specifically require a lockout station, but keeping all equipment at a visible, fixed location near the work area makes compliance practical and is generally considered a best practice.

Sources

1. OSHA, 29 CFR 1910.147 Control of Hazardous Energy (Lockout/Tagout): 29 CFR 1910.147 requires equipment-specific written energy control procedures, defines the six-step energy control sequence, the lockout preference over tagout, employee categories, group lockout, shift-change procedures, verification, training, and annual periodic inspection requirements
2. OSHA, FY2023 Top 10 Most Cited Standards: OSHA's 1910.147 Lockout/Tagout is consistently among the top five most-cited general industry violations; more than 2,500 citations were issued in FY2023
3. OSHA, Lockout/Tagout Safety and Health Topics Page: OSHA estimates proper LOTO procedures could prevent approximately 120 fatalities and 50,000 injuries annually; the standard covers approximately 3 million workers
4. OSHA, Penalties: OSHA serious violation penalties up to $16,131 per violation; willful or repeated violations up to $161,323 per violation as of 2024 penalty levels
5. OSHA, Letter of Interpretation: 1910.147(c)(4) exception for single energy source machines: OSHA letter of interpretation clarifying that the exception to the written procedure requirement under 1910.147(c)(4)(i) is narrow and most industrial equipment will not qualify
6. OSHA, 29 CFR 1910.303 Electrical Safety Standards: OSHA electrical safety standards 1910.303 through 1910.399 apply to electrical work on systems and supplement 1910.147 for machines with electrical energy sources
7. Bureau of Labor Statistics, Census of Fatal Occupational Injuries: BLS occupational injury and fatality data used to contextualize energy-control-related fatality estimates in manufacturing and general industry
8. OSHA, Lockout/Tagout eTool: OSHA's interactive eTool covers equipment-specific procedure development, hardware requirements, and training elements for LOTO compliance