Lockout/Tagout to Prevent Equipment Activation
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-energised and safe to work on.
Identify the Hazards
- Unexpected Activation: Machines starting up during maintenance or servicing due to a failure to isolate power.
- Stored Energy Release: Hazardous energy—such as pressure, electrical charge, or mechanical force—releasing suddenly.
- Improper Tagging: Incomplete or unclear tagging of equipment, leading to accidental re-energisation.
Safety Practices and Preventative Measures
To mitigate these hazards, always follow these steps:
Understand When to Use LOTO:
Use lockout/tagout procedures whenever servicing, maintaining, or cleaning equipment that could start unexpectedly or release hazardous energy.
Follow LOTO Procedures:
- Notify All Affected Workers: Let everyone in the area know that equipment will be shut down and locked out.
- Power Down Equipment: Turn off the machine using its standard operating controls.
- Isolate the Energy Source: Fully disconnect the equipment from its energy source (e.g. electrical, pneumatic, or hydraulic supply).
- Apply Locks and Tags: Attach locks and clearly marked tags to energy-isolating devices. Tags must state the reason for the lockout.
- Release Stored Energy: Safely release any residual or stored energy (e.g. bleed off pressure, discharge capacitors).
- Verify Isolation: Test the equipment to confirm it is fully de-energised before beginning work.
Never Deviate from Procedure:
- Do not bypass, remove, or ignore locks and tags unless you are the authorised person performing LOTO removal.
Properly Remove Locks and Tags:
- After work is complete, ensure all personnel are clear, all tools are removed, and the system is safe.
- Only then should locks and tags be removed—this must follow your company’s LOTO procedure.
Real-Life Case or Scenario
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-energised 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.
- Use only approved company locks and tags—never makeshift devices.
- Confirm all energy sources are fully isolated before starting work.
- Report any defective or missing LOTO equipment immediately.
Employer Responsibilities
- Provide training and refresher courses on lockout/tagout procedures.
- Supply the correct LOTO equipment and ensure it is maintained.
- Make written procedures accessible and specific to each piece of equipment.
- 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 Health and Safety at Work Act 2015 (HSWA), PCBUs (Persons Conducting a Business or Undertaking) must manage the risks associated with hazardous energy. Lockout/tagout (also referred to as isolation and de-energisation) 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 authorised, trained persons isolate and re-energise plant and equipment
Disclaimer
These toolbox talks are provided for informational and educational purposes only and are not a substitute for professional legal, health and safety, or regulatory advice.
The content reflects recognised best practices and general industry standards as at the date of publication. However, it may not be applicable to all workplace environments or specific operational contexts.
It is the responsibility of the Person Conducting a Business or Undertaking (PCBU), as well as officers, workers, and other duty holders under the Health and Safety at Work Act 2015 (HSWA), to ensure compliance with all relevant laws, regulations, and WorkSafe New Zealand guidance.
The authors, presenters, and distributors of this toolbox talk disclaim all liability for any loss, damage, or injury arising from the use or reliance on the information provided. Users should seek advice from a suitably qualified health and safety professional or legal advisor for guidance tailored to their specific circumstances.
Always follow your organisation’s policies, procedures, and safe work practices to manage risks and maintain a safe and healthy workplace.
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