Lockout and Tagout Procedure HSE Training
Slide 1: Lockout and Tagout (LOTO) Procedure – HSE Training
Presented by: HSE STUDY GUIDE
Date: 26/04/2025
Good morning team!
I hope everyone is doing great today.
This morning, we’re going to talk about a life-saving procedure — Lockout and Tagout (LOTO).
This procedure is critical whenever we’re working on equipment that could start up unexpectedly or release stored energy.
Following LOTO isn’t just a rule — it’s how we protect lives, including our own.
Let’s dive in.
Slide 2: Objectives of Today’s Training
By the end of this session, you’ll understand:
- What Lockout and Tagout (LOTO) is
- Why LOTO is critical for your safety
- The steps to properly apply and remove LOTO
- Common mistakes and how to avoid them
- Emergency procedures related to LOTO
Slide 3: What is Lockout and Tagout (LOTO)?
Lockout:
Physically locking equipment in a safe or “off” position so it cannot be operated.
Tagout:
Placing a warning tag on the energy-isolating device to inform others that equipment must not be operated.
Together, LOTO protects workers from accidental start-up, energy release, and serious injuries.
Slide 4: Why LOTO is Necessary
Unexpected equipment startup or stored energy release can cause:
- Electrocution
- Crushing injuries
- Burns
- Amputations
- Fatalities
LOTO is our first line of defense when repairing, maintaining, or cleaning machines.
Slide 5: Common Types of Hazardous Energy
LOTO protects against all types of hazardous energy, including:
- Electrical energy
- Mechanical energy (moving parts)
- Hydraulic and pneumatic energy (pressurized fluids or air)
- Thermal energy (hot surfaces, steam)
- Chemical energy (reactive substances)
- Gravity (falling objects)
Energy can be hidden — never assume it’s safe just because it’s turned off.
Slide 6: When to Apply LOTO
Use LOTO procedures when:
- Performing maintenance or repairs
- Cleaning machinery
- Clearing jams or blockages
- Installing new equipment
- Performing inspections where accidental movement could cause injury
If you need to place hands, tools, or body parts into machinery — you need LOTO.
Slide 7: The Six Basic Steps of LOTO
- Prepare for Shutdown:
- Identify all energy sources. Understand the machine and its hazards.
- Shut Down the Equipment:
- Turn off the machine following standard procedures.
- Isolate the Energy Sources:
- Physically disconnect or block energy sources.
- Apply Lockout/Tagout Devices:
- Attach your personal lock and a tag clearly stating your name and purpose.
- Release Stored Energy:
- Bleed off, drain, or otherwise neutralize any residual energy.
- Verify Isolation:
- Try to operate the machine (test attempt) to confirm that it won’t start.
Verification is critical — never skip this step.
Slide 8: Personal Lock and Tag Responsibility
- Each worker must apply their own personal lock and tag.
- One lock, one person, one key — no shared locks!
- Never remove someone else’s lock or tag — only the person who installed it can remove it.
If you’re not locked out, you are not protected.
Slide 9: Important Tag Information
Tags must clearly state:
- The name of the person who applied the lock
- The date and time of application
- The reason for the lockout
Tags should be durable, weatherproof, and highly visible.
Slide 10: Common LOTO Mistakes to Avoid
- Forgetting to verify isolation
- Not controlling all energy sources
- Using someone else’s lock
- Removing your lock before the work is complete
- Assuming it’s safe just because equipment is off
Remember, assumptions can be deadly. Always follow the full procedure.
Slide 11: Group Lockout Procedures
When multiple workers are involved:
- A group lockbox can be used
- The primary authorized employee locks the energy source and places the key in the lockbox
- Each worker places their own personal lock on the lockbox
- No one removes their lock until their work is complete
Teamwork in LOTO means everyone stays protected.
Slide 12: Special Situations
LOTO must also be applied in special cases like:
- Shift changes (locks must be transferred properly)
- Temporary removal of locks for testing (must follow strict procedures)
- Contractors working on site (must follow our LOTO system)
Every situation must have a clear, agreed-upon plan.
Slide 13: Emergency Removal of Locks
If a worker forgets to remove their lock:
- Verify the worker is not on site
- Attempt to contact the worker
- Supervisor and safety officer must jointly remove the lock following documented procedures
- Complete a full incident report
This is a last resort and must be taken very seriously.
Slide 14: Real-Life Example
Here’s a quick story…
A worker thought a conveyor was de-energized. He reached in to remove a jam, and the machine started unexpectedly. His arm was caught and seriously injured.
Investigation showed no LOTO was applied — only a verbal warning had been given.
The lesson?
Lock it out. Tag it out. Test it. Always.
Slide 15: Final Safety Reminders
- Always follow the six steps of LOTO
- Never remove someone else’s lock or tag
- If unsure — STOP and ask
- Remember: No shortcut is worth your life
When you use LOTO properly, you control the hazard, not the other way around.
Slide 16: Questions and Discussions
Now, I’d like to open the floor:
Any questions, thoughts, or experiences you want to share about LOTO?
Have you ever seen unsafe LOTO practices on a job site?
Let’s discuss — your input is valuable.
Slide 17: Thank You
Thank you for your attention and focus today.
LOTO might seem simple, but it’s one of the most powerful tools we have for preventing serious accidents.
Let’s stay disciplined, stay sharp, and lock out hazards before they lock you out of life.
Follow HSE STUDY GUIDE for more daily safety talks and videos!
Stay safe out there!
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