Lockout Tagout (LOTO) Procedure Template
A lockout tagout procedure tells a technician exactly how to isolate every energy source on one machine before work starts. This template builds a clean, postable procedure with energy sources, isolation sequence, verification and restart, plus a lock log and an annual inspection record.
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Lockout Tagout (LOTO) Procedure Template
Lockout Tagout Energy Control Procedure
Company: Acme Precision Ltd Procedure no.: LOTO-014 Revision: Rev A Effective: 2026-10-20 Machine: Hydraulic Press P-14 Asset ID: EQ-00514 Location: Building 2, Bay C
Purpose and scope
This procedure sets out the steps to shut down, isolate, block and secure Hydraulic Press P-14 to control hazardous energy before servicing or maintenance, in line with the employer energy control program. It applies to: Maintenance technicians trained in LOTO.
Energy sources and locations
Electrical: main disconnect DS-14 on east wall. Hydraulic: pump motor and accumulator, pressure gauge on manifold. Pneumatic: air supply valve V-3 at drop. Gravity: ram in raised position must be blocked.
Shutdown and isolation sequence
1. Stop the press at the operator station. 2. Turn main disconnect DS-14 to OFF. 3. Close and lock air supply valve V-3, bleed the line. 4. Lower the ram or install the ram block, then relieve hydraulic pressure at the manifold.
Lock and tag application
| Isolation point | Device | Lock / tag no. | Applied by | Time |
|---|---|---|---|---|
| Main disconnect | Lock and tag | |||
| Air supply valve | Lock and tag | |||
| Hydraulic manifold | Tag and bleed | |||
| Ram block | Physical block |
Stored energy and verification
Attempt start at the operator station and confirm no movement. Check pressure gauge reads zero. Test for absence of voltage at the disconnect load side with a rated meter.
Restoring equipment to service
Remove tools and ram block, confirm guards are in place, check that all personnel are clear, notify affected employees, remove locks and tags by the person who applied them, and energize.
Periodic inspection record
| Inspection date | Authorized employee observed | Inspector | Result | Notes |
|---|---|---|---|---|
Approvals
A starting point, not legal advice. Machine-specific procedures must reflect the actual equipment, and the employer program must meet 29 CFR 1910.147 or the applicable standard in your jurisdiction. Review with authorized employees and check the procedure at least annually.
Link LOTO procedures to maintenance work orders
An optional look at attaching the right isolation procedure to each work order in your ERP.
Optional. The tool and every export work without this. No spam.
How to use this template
Walk the machine with a maintenance technician and an operator. List every energy source: electrical, hydraulic, pneumatic, gravity, springs, thermal and chemical. Fill in the fields, one machine per procedure, and write the isolation steps in the actual order a person would perform them. Export to PDF or Word, laminate the copy for the machine, and keep the controlled copy in your document system. The lock table lets each authorized employee record their lock number and time on every isolation point.
The standard behind it
In the US, 29 CFR 1910.147 requires an energy control program with documented procedures, employee training and periodic inspection at least annually. Its core sequence is: prepare, notify affected employees, shut down, isolate, apply lockout or tagout devices, release or restrain stored energy, and verify isolation before work starts. A minor servicing exception exists, and an exemption from detailed documentation applies only when specific criteria are all met, so most plants write a procedure for each machine.
- Each authorized employee applies a personal lock
- Locks and tags are removed by the person who applied them
- Verify by trying to start the machine, with controls returned to off
- Group lockout and shift change need extra rules
Worked example
For a hydraulic press, the template captures the electrical disconnect, the air valve, the accumulator, and the raised ram as a gravity hazard. The isolation sequence blocks the ram before pressure is bled, and the verification step checks the gauge reads zero as well as testing for voltage. That combination of a try-start check plus a stored-energy check is what auditors most often find missing in generic procedures.
Common mistakes
Generic procedures that say isolate all energy sources are not machine specific and are a frequent citation. Others include forgetting stored energy such as capacitors or accumulators, tagging without locking when a lock is feasible, leaving out the restart notification, and never performing the annual inspection. Tie the procedure number to the asset ID in your maintenance system so a work order can reference the correct LOTO document.
Frequently Asked Questions
Do I need a written procedure for every machine?
Generally yes. 29 CFR 1910.147 allows an exception from documenting only if eight conditions are all met, such as a single energy source and no potential for stored energy. Most plants find it simpler to document every machine.
How often must LOTO procedures be inspected?
At least once a year, by an authorized employee other than the one using the procedure. For lockout, the inspector reviews the steps with each employee, and the inspection is certified with the date and equipment.
What is the difference between lockout and tagout?
A lock physically holds the energy isolating device in the safe position. A tag is a warning only. Where a device can be locked out, the program must use a lock, unless the employer can show tagout gives equal protection.
Who can remove a lock?
The authorized employee who applied it. Your program should define a documented, controlled removal procedure for the rare case when that person is not available, including checks that the employee has left the site.
If your maintenance work orders live in an ERP, we can help link each work order to the right LOTO procedure and approval so it prints with the job.
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