Lockout/Tagout to Prevent Equipment Activation

Housekeeping & Site Organization
English (Canada)

The Problem

Unexpected equipment activation is one of the leading causes of workplace injuries and fatalities. Without proper lockout/tagout (LOTO) procedures, workers are at risk of serious harm, including amputations, electrocution, or being caught in moving machinery. Today, we’ll discuss how LOTO procedures protect you and ensure equipment is de-energized and safe to work on.

Identify the Hazards

  • Unexpected Activation: Machines starting up during maintenance or servicing due to a failure to isolate power.
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  • Stored Energy Release: Hazardous energy—such as pressure, electrical charge, or mechanical force—releasing suddenly.
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  • Improper Tagging: Incomplete or unclear tagging of equipment, leading to accidental re-energization.

Safety Practices and Preventative Measures

Understand When to Use LOTO:

  1. Use lockout/tagout procedures whenever servicing, maintaining, or cleaning equipment that could start unexpectedly or release hazardous energy.

Follow LOTO Procedures:

  1. Notify All Affected Workers: Let everyone in the area know that equipment will be shut down and locked out.
  2. Power Down Equipment: Turn off the machine using its standard operating controls.
  3. Isolate the Energy Source: Fully disconnect the equipment from its energy source (e.g., electrical, pneumatic, or hydraulic supply).
  4. Apply Locks and Tags: Attach locks and clearly marked tags to energy-isolating devices. Tags must state the reason for the lockout.
  5. Release Stored Energy: Safely release any residual or stored energy (e.g., bleed off pressure, discharge capacitors).
  6. Verify Isolation: Test the equipment to confirm it is fully de-energized before beginning work.

Never Deviate from Procedure:

  1. Do not bypass, remove, or ignore locks and tags unless you are the authorized person performing LOTO removal.

Properly Remove Locks and Tags:

  1. After work is complete, ensure all personnel are clear, all tools are removed, and the system is safe.
  2. Only then should locks and tags be removed—this must follow your company’s LOTO procedure.

Real-Life Case or Scenario

Where possible, use an actual incident that you have experienced or been involved in.

A maintenance worker suffered fatal injuries when a machine unexpectedly started during servicing. The worker failed to correctly lock out the equipment, and another employee unknowingly re-energized the system. This tragedy highlights why strict adherence to lockout/tagout procedures is essential.

Employee Responsibilities

  • Follow LOTO procedures every time you service or maintain equipment.
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  • Use only approved company locks and tags—never makeshift devices.
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  • Confirm all energy sources are fully isolated before starting work.
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  • Report any defective or missing LOTO equipment immediately.

Employer Responsibilities

  • Provide training and refresher courses on lockout/tagout procedures.
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  • Supply the correct LOTO equipment and ensure it is maintained.
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  • Make written procedures accessible and specific to each piece of equipment.
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  • Regularly audit and update the LOTO programme to address any issues.

Discussion & Questions

  • "What challenges have you faced when implementing lockout/tagout procedures?"
  • "Have you seen or experienced incidents involving unexpected equipment activation?"

Encourage workers to raise concerns or share experiences to improve safety practices.

Commitment/Action Plan

Starting today, let’s commit to using lockout/tagout procedures for every applicable task. If you are ever unsure about the process or the equipment, stop and ask your supervisor for clarification. Safety starts with all of us.

Wrap-Up

Lockout/tagout is one of the most effective ways to prevent serious injury on-site. Following these procedures is not just about compliance—it’s about making sure we all go home safely at the end of the day. Thank you for your time and commitment to safety.

Standards Overview

Under the Canada Labour Code and provincial occupational health and safety regulations, employers must manage the risks associated with hazardous energy. Lockout/tagout (also referred to as isolation and de-energization) is a critical control to:

  • Prevent accidental startup of machinery during servicing or cleaning
  • Control the release of stored energy in systems
  • Ensure that only authorized, trained persons isolate and re-energize plant and equipment

Disclaimer

“The information provided in this toolbox talk is intended for informational and educational purposes only. It is not a substitute for professional legal, safety, or regulatory advice. The content reflects general best practices and industry standards but may not be applicable to all workplace environments or jurisdictions.

It is the responsibility of employers, supervisors, and workers to ensure compliance with applicable federal, provincial, and territorial laws, regulations, and standards, including but not limited to those set by the Canadian Centre for Occupational Health and Safety (CCOHS) and relevant provincial occupational health and safety authorities. Site App Pro, its affiliates, agents, or representatives—as well as the authors, presenters, and distributors of this toolbox talk—assume no liability for the use or application of the information provided.

Participants are strongly encouraged to consult appropriate legal, safety, or regulatory professionals regarding specific workplace concerns or questions. Always adhere to your organisation’s policies and procedures for health and safety and hazard management.

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Last Updated:
July 4, 2025