What Is Lockout Tagout (LOTO)? Steps, Devices & Training

Machines are dangerous when they are running, but they can also be dangerous when they are “off”. If someone switches a machine back on, or stored energy is suddenly released, a worker inside or near it can be crushed, cut, burned or electrocuted. Lockout tagout is how workers make sure that cannot happen.

Lockout means placing a lock on an energy-isolating device, such as a disconnect switch or a valve, so it stays in the safe position. Tagout means attaching a tag that warns others not to operate the equipment and shows who applied the lock. A tag on its own does not stop anything, so locks are the main protection and tags give the information.

In Canada, the national standard for this work is CSA Z460, Control of hazardous energy: Lockout and other methods. Each province and territory also has OHS regulations that set lockout rules for employers. Employers must have written lockout procedures for their equipment and train workers to follow them.

A machine can have more than one energy source. Every one of them must be found and controlled before work starts.

Stored energy is the one people forget. Turning off the power does not always make a machine safe. Springs, raised parts, pressure in lines and charged capacitors can still release energy. That is why every lockout includes a step to release or block stored energy.

Your workplace’s written procedure is the one you follow, but most lockouts use the same basic steps:

1. Prepare. Know the machine, every energy source and the hazards. Tell affected workers.
2. Shut down the equipment using its normal stopping method.
3. Isolate every energy source, for example by opening disconnects and closing valves.
4. Apply locks and tags. Each worker puts on their own personal lock and tag.
5. Release or block stored energy by bleeding pressure, discharging capacitors, blocking raised parts and releasing springs.
6. Verify that the equipment is isolated. Try to start it, or test it, then return the controls to off.

A key rule is one worker, one lock, one key. Each person working on the equipment applies their own lock and keeps the only key. No one else removes it. For large jobs, a group lockout uses a lockbox or a multi-lock hasp so everyone is protected until the last person is finished.

Removing locks is just as important as applying them. Before a lock comes off, the work must be finished, tools and guards put back, and every worker clear of the machine. Each worker removes only their own lock. Affected workers are told that the equipment is about to start, and only then is energy restored and the machine returned to normal service.

Lockout uses simple tools, but each one has a job:

• Personal safety padlocks, each keyed differently and assigned to one worker.
• Tags that show the worker’s name, the date and the reason for the lockout.
• Hasps that let several workers lock the same isolation point.
• Valve covers, breaker locks and plug locks that hold switches, valves and plugs in the off position.
• Group lockboxes that hold keys during a group lockout.

Devices must be strong enough that they cannot be removed without a lot of force, and they should only be used for lockout.

Anyone who services, repairs, adjusts, clears jams on or cleans equipment, and anyone who works near it, needs to understand lockout. Common roles include:

There are two layers of training. A general LOTO course teaches the principles, energy types, devices and steps. Your employer must also train you on the written lockout procedures for the specific machines at your workplace.

The Gama Safety Lock Out / Tag Out course takes about four hours and has nine modules:

1. Introduction to Lockout Tagout: what lockout and tagout mean, and when a lockout is needed.
2. Understanding Hazardous Energy: the main forms of energy, including stored energy.
3. LOTO Devices and Equipment: locks, tags, hasps, valve covers and other devices.
4. LOTO Procedures: the step-by-step process, from shutdown to applying locks and tags.
5. Performing Lockout Tagout: releasing stored energy and verifying equipment cannot start.
6. Releasing from Lockout Tagout: removing locks safely and returning equipment to service.
7. Incident Reporting and Record Keeping: reporting incidents and near misses.
8. Case Studies and Practical Applications: real-world lockouts and what went wrong.
9. Common Challenges and Solutions: shift changes, group lockouts and contractors.

There is no single national expiry date for a lockout certificate. How often you retrain depends on your province and your employer. Many employers ask for a refresher every 1 to 3 years, and workers should be retrained when equipment, procedures or hazards change, or when someone is seen not following the procedure.

1. Enrol in the online Lock Out / Tag Out course and start right away on any device.
2. Learn at your own pace. Your progress saves automatically, so you can do it in short sessions.
3. Pass the final exam with 80% or better. Retakes are unlimited and free.
4. Download your certificate right away. A physical wallet card is mailed to you free.

The course is WorkSafe-aligned, recognized by employers across Canada, and available in English, French, Spanish, Punjabi, Hindi, Mandarin and more. Training a crew? Team pricing starts at 2 seats, with an admin dashboard. Call 1-866-661-9803 or email info@gamasafety.ca.