Have you ever seen someone doing maintenance on a machine while it’s still connected to power? ⚡
That’s one of the biggest safety mistakes at work.
Many accidents happen when machines start unexpectedly — crushing, cutting, or shocking workers.
That’s why we follow a simple but powerful rule called Lockout Tagout (LOTO).
It means: switch off, lock it, and tag it — before you touch it.
⚙️ What Is Lockout Tagout?
Lockout Tagout (LOTO) is a safety process used before doing maintenance or repair work.
It makes sure that all energy sources (like electricity, steam, gas, pressure, etc.) are turned off and locked so the machine can’t start accidentally.
In simple words:
“If it can move, it must be locked before you start work.” 🔒
⚡ Why LOTO Is Important
Without LOTO, stored energy can release suddenly.
For example:
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A valve may open by mistake.
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A motor may start automatically.
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A steam line may still have pressure.
Even a small mistake can cause serious injury or death.
That’s why every worker must understand and follow LOTO properly.
🧩 Step-by-Step Lockout Tagout Procedure
1️⃣ Prepare for Shutdown
Know what energy you are isolating — electrical, mechanical, hydraulic, or pneumatic.
Identify where the main switch, valve, or breaker is located.
2️⃣ Switch Off the Equipment
Turn off the machine using normal controls like stop buttons or switches.
3️⃣ Isolate the Energy Source
Physically disconnect or close the valve, circuit breaker, or air supply.
4️⃣ Apply Lock and Tag
Use your personal safety lock and attach a warning tag with your name, department, and reason for isolation.
🔖 The tag should clearly say: “DO NOT OPERATE – UNDER MAINTENANCE.”
5️⃣ Release Stored Energy
Discharge any leftover pressure, air, or electricity in the system.
6️⃣ Test Before Starting Work
Check that the machine doesn’t start when you press the start button.
Only then begin your work safely.
🧰 Before Restarting the Machine
When maintenance is complete:
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Remove all tools and materials.
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Make sure everyone is clear from the area.
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Each worker must remove only their own lock.
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Inform the supervisor before starting the machine again.
Never remove someone else’s lock without written permission! 🚫
💡 Real Example
At a fertilizer plant, a technician started cleaning a pump that wasn’t locked out.
The pump suddenly started — luckily, he escaped with minor injuries.
After that, the company made it a rule:
“No Lock, No Work.”
✅ Simple Tips for LOTO Safety
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Always use your personal safety lock and key.
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Never depend on someone else’s isolation.
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Keep extra locks and tags available in maintenance areas.
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Train all staff regularly on LOTO procedures.
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Maintain a register of isolation points.
⚠️ Common Mistakes to Avoid
❌ Forgetting to test after isolation.
❌ Sharing the same lock among team members.
❌ Not tagging the lock with details.
❌ Removing another person’s lock.
Remember: Your lock is your life 🔒❤️
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