Full definition
Lockout/Tagout (LOTO) is a critical safety procedure designed to ensure that hazardous energy sources are properly controlled during maintenance activities. The LOTO process involves a series of steps that help prevent the accidental release of energy that could cause injury or death to workers. This procedure applies to various energy types, including electrical, pneumatic, hydraulic, mechanical (such as springs), gravitational, thermal, and chemical. By following LOTO protocols, maintenance personnel can safely perform repairs or adjustments without the risk of unexpected machine startup or release of stored energy.
The LOTO procedure begins with the identification of all energy sources associated with the equipment being serviced. Once identified, the next step is to isolate these energy sources to prevent any accidental activation. This is typically done by shutting down the equipment and disconnecting it from its energy source. After isolation, maintenance personnel must then apply a personal padlock to the energy-isolating device, ensuring that only they can remove it. Additionally, a tag must be attached to communicate to others that maintenance work is in progress and that the equipment should not be operated until the tag is removed.
Verification of zero energy is an essential final step in the LOTO procedure. This involves attempting to start the equipment to confirm that all energy sources have been effectively controlled and that the equipment is safe for maintenance. Failure to adhere to LOTO protocols can lead to severe injuries or fatalities; statistics show that LOTO failures account for approximately 10% of industrial fatalities in the United States and Mexico. Therefore, strict compliance with LOTO procedures is necessary to safeguard workers during maintenance activities. The procedure is governed by various regulations, including NOM-004-STPS in Mexico and OSHA 29 CFR 1910.147 in the United States, which set forth guidelines and requirements for effective lockout/tagout practices.