Lockout tagout procedure template

First, conduct an equipment energy audit to identify all power sources. For each machine, document the exact locations of disconnect points, valves, and energy isolation devices. Add equipment-specific details to each step, including photos of isolation points when possible. Remember to involve experienced operators and maintenance staff who understand the equipment’s energy hazards.

Your procedures should be developed by a team including maintenance supervisors, safety professionals, and equipment operators who understand the machinery. This collaborative approach ensures procedures are both technically accurate and practical. While safety managers typically coordinate the documentation process, input from those who regularly service the equipment is crucial for creating effective, realistic procedures.

Lockout involves placing a physical lock on energy-isolating devices, preventing equipment activation. Tagout uses warning tags when locks cannot be applied. This template accommodates both approaches, though lockout is preferred for its physical barrier. Remember that if you use tagout alone, OSHA requires additional protective measures to provide equivalent safety to lockout.

Training should include hands-on practice with actual equipment and locks. Walk through each step of your procedures, demonstrate proper isolation techniques, and have employees perform lockout under supervision. Focus on energy identification, proper sequence, and verification methods. Create equipment-specific training modules and test comprehension through practical demonstrations rather than just written tests.