Manufacturing Lockout/Tagout (LOTO) Procedure Checklist

This comprehensive lockout/tagout (LOTO) checklist ensures 100% compliance with OSHA 29 CFR 1910.147 Control of Hazardous Energy standard. Covers all seven steps required by OSHA including hazardous energy identification, equipment shutdown, energy isolation, lockout device application, stored energy dissipation, verification of isolation, and safe work authorization. Also compliant with ANSI/ASSE Z244.1 and Canadian CSA Z460.

  • Industry: Manufacturing
  • Frequency: Each Maintenance Activity
  • Estimated Time: 15-30 minutes
  • Role: Maintenance Technician / Authorized Employee
  • Total Items: 54
  • Compliance: OSHA 29 CFR 1910.147, OSHA 29 CFR 1910.269 (Electric Power), ANSI/ASSE Z244.1, CSA Z460 (Canada), AS 4024 (Australia)

Step 1: Preparation

Identify energy sources and plan lockout.

  • Equipment-specific LOTO procedure reviewed?
  • All energy sources identified?
  • Electrical energy present?
  • Mechanical energy present?
  • Hydraulic energy present?
  • Pneumatic energy present?
  • Thermal energy present?
  • Chemical energy present?
  • Stored/potential energy (gravity, springs)?
  • Affected employees notified of lockout?

Step 2: Equipment Shutdown

Orderly shutdown of equipment.

  • Normal shutdown procedure followed?
  • All operators clear of equipment?
  • All operating controls in OFF position?
  • Shutdown Completed Time

Step 3: Energy Isolation

Isolate equipment from energy sources.

  • Electrical disconnects opened/OFF?
  • Circuit breakers OFF?
  • Isolation valves closed?
  • Blanks/blinds installed (if required)?
  • Pneumatic lines disconnected/bled?
  • Hydraulic pressure relieved?

Step 4: Lockout/Tagout Application

Apply locks and tags to energy isolating devices.

  • Locks applied to all energy isolating devices?
  • Tags applied with employee name and date?
  • Each authorized employee applied their own lock?
  • Photo of Applied Locks/Tags
  • Number of Locks Applied
  • Lock Numbers/IDs

Step 5: Stored Energy Release

Release or restrain all stored/residual energy.

  • Capacitors discharged or grounded?
  • Springs released or blocked?
  • Elevated parts lowered or blocked?
  • All pressure relieved (hydraulic, pneumatic)?
  • Temperature at safe level?
  • Lines bled/drained as required?

Step 6: Verification

Verify zero energy state.

  • Operating controls tested to verify de-energization?
  • Voltage tested with meter (if electrical)?
  • Pressure gauges verified at zero?
  • Controls returned to OFF after testing?
  • Equipment verified safe to work on?
  • Verification Completed Time

Step 7: Work Completion & Removal

Restore equipment after maintenance.

  • Maintenance/service work complete?
  • All tools and materials removed?
  • Guards and safety devices replaced?
  • All employees clear of equipment?
  • Affected employees notified before removal?
  • Locks removed by each authorized employee?
  • Equipment tested for proper operation?
  • LOTO Removal Completed Time

Training Verification

Verify training and inspection requirements.

  • Authorized employee training current?
  • Affected employee awareness training complete?
  • Periodic inspection within last 12 months?
  • Group lockout procedures understood (if applicable)?

Energy Control Permit

Verify energy control permit requirements.

  • Energy control permit issued?
  • All energy sources listed on permit?
  • Permit signed by supervisor?
  • Permit posted at equipment?

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Why Use This Manufacturing Lockout/Tagout (LOTO) Procedure Checklist?

This manufacturing lockout/tagout (loto) procedure checklist helps manufacturing teams maintain compliance and operational excellence. Designed for maintenance technician / authorized employee professionals, this checklist covers 54 critical inspection points across 9 sections. Recommended frequency: each maintenance activity.

Ensures compliance with OSHA 29 CFR 1910.147, OSHA 29 CFR 1910.269 (Electric Power), ANSI/ASSE Z244.1, CSA Z460 (Canada), AS 4024 (Australia), NFPA 70E, ISO 45001. Regulatory-aligned for audit readiness and inspection documentation.

Frequently Asked Questions

What does the Manufacturing Lockout/Tagout (LOTO) Procedure Checklist cover?

This checklist covers 54 inspection items across 9 sections: Step 1: Preparation, Step 2: Equipment Shutdown, Step 3: Energy Isolation, Step 4: Lockout/Tagout Application, Step 5: Stored Energy Release, Step 6: Verification, Step 7: Work Completion & Removal, Training Verification, Energy Control Permit. It is designed for manufacturing operations and compliance.

How often should this checklist be completed?

This checklist should be completed each maintenance activity. Each completion takes approximately 15-30 minutes.

Who should use this Manufacturing Lockout/Tagout (LOTO) Procedure Checklist?

This checklist is designed for Maintenance Technician / Authorized Employee professionals in the manufacturing industry. It can be used for self-assessments, team audits, and regulatory compliance documentation.

Can I download this checklist as a PDF?

Yes, this checklist is available as a free PDF download. You can also use it digitally in the POPProbe mobile app for real-time data capture, photo documentation, and automatic reporting.

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