LOTO Periodic Inspection Checklist (Free, PDF)

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Written program and procedures

A written energy control program exists and is currentCRITICALA machine-specific energy control procedure exists for each machine or equipment group, or the exception is documentedCRITICALEach procedure identifies the scope, purpose and authorizationCRITICALEach procedure lists all energy sources (electrical, hydraulic, pneumatic, mechanical, thermal, chemical, gravity, stored)CRITICALProcedures give specific steps for shutdown, isolation, blocking and securingProcedures give specific steps for placing, removing and transferring lockout and tagout devicesProcedures state how to verify the isolation (try-out, test for zero energy)CRITICALProcedures include release from lockout steps (check area, check employees, remove devices)Procedures have been updated after any machine or process change

Devices and hardware

Locks and tags are durable and suitable for the environmentLocks and tags are standardized by color, shape or size and used only for energy controlDevices identify the employee who applied themDevices are substantial enough to prevent removal without excessive forceTags warn against starting and are not removable by hand once attachedLockout points on equipment are labeled and accessibleEnough locks, hasps and group lock boxes are available at the point of useDamaged or missing devices are replaced

Training and authorized employees

Authorized employees are trained in the energy control procedure and hazardsCRITICALAffected employees are trained to recognise lockout and not restart equipmentCRITICALOther employees in the area are instructed on the prohibition of restarting locked out equipmentRetraining is done after changes in job, equipment, process or proceduresRetraining is done when the periodic inspection shows deviations or inadequate knowledgeTraining records show name, date and content

Group, shift and contractor control

Group lockout procedures give each person a personal lock on the group box or haspCRITICALAn authorized employee is assigned overall responsibility for each group lockoutShift or personnel changes have a defined handover so protection is continuousContractors and host employers exchange their lockout proceduresContractor work is covered by an agreed process before it startsLock removal when the owner is absent follows the documented procedureCRITICAL

Periodic inspection and records

Periodic inspections are carried out at least annuallyCRITICALEach inspection is done by an authorized employee who is not using the procedure being inspectedThe inspection reviews each authorized employee's responsibilities under the procedureGroup lockout inspections include a review with each employee involvedInspection is documented: machine, date, employees included and inspectorCorrective actions from the last inspection are closedIncidents and near misses involving energy release are fed back into procedures

Count the items marked complete. Any unchecked critical item should have a corrective action and an owner before the inspection is signed off. This checklist is a working aid based on the structure of the OSHA lockout/tagout rule (29 CFR 1910.147); check the current regulation and any local or state requirements.

Link safety procedures to work orders

Optional: talk to us about attaching energy control procedures to equipment and tasks in your ERP.

Optional. The tool and every export work without this. No spam.

How to run the inspection

Choose a machine or procedure, walk the actual isolation points with the authorized employee, and compare what they do with what the written procedure says. The inspector should not be a person who normally uses that procedure. Tick items as you verify them, note findings against the machine, and keep the completed form as the inspection record with the date, machine, inspector and employees included.

Inspect at least annually, or more often if incidents or changes occur
Observe, do not only read the procedure
Ask the employee to explain each energy source and the verification step
Record who was inspected and who inspected

What the rule expects

The OSHA standard in 29 CFR 1910.147 requires an energy control program, machine-specific procedures (with a limited exception for simple equipment), training, and periodic inspection at least annually. The inspection is meant to correct deviations or inadequacies in the procedure and in employee knowledge. Other countries and some US states have their own rules and different terms, so confirm which applies to your site.

Typical findings

Common failures are procedures that list only the electrical source and miss stored hydraulic or pneumatic energy, missing try-out steps, a single lock used for several people, contractor crews working under no shared procedure, and worn tags that cannot be read. Another is a procedure copied from a similar machine that has since been modified. Each finding should have an owner and a due date.

Connecting it to maintenance planning

Where possible, attach the correct energy control procedure to the maintenance task in your CMMS or ERP so the planner can print it with the work order. Review procedures when a modification or engineering change is closed. This keeps the document set tied to the equipment records instead of a separate folder that goes out of date.

Frequently Asked Questions

How often must LOTO procedures be inspected?

Under the OSHA rule in 29 CFR 1910.147, the periodic inspection must be done at least once a year for each energy control procedure. Many sites inspect high-risk machines more often, and after incidents or equipment changes.

Who may perform the periodic inspection?

An authorized employee who is not one of the employees using the procedure being inspected. That gives an independent look at whether the procedure and the practice match. Check your local regulation for exact wording.

Do I need a procedure for every machine?

In general yes, though the standard has a limited exception for simple equipment that meets listed conditions, and similar machines can share a procedure if the steps are the same. Document the reasoning for any exception.

Is this checklist legal advice?

No. It is a working aid built on the structure of the rule. Regulations change and vary by jurisdiction, so check the current text and consult your EHS adviser for your specific obligations.

If you want procedures linked to equipment and work orders in your ERP so inspections are scheduled and tracked, we can discuss how to set that up.

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LOTO Lockout Tagout Periodic Inspection Checklist