OSHA Lockout Tagout

By R.W. Hurst, Editor

The OSHA Lockout Tagout (LOTO) regulation is designed to help companies prevent workplace injuries caused by the unexpected startup or release of hazardous energy. This article explains OSHA’s goals behind the rule, highlights the types of energy it covers, and explores why lockout tagout procedures are essential for employee safety. LOTO represents a foundational component of any effective industrial safety program, from improving compliance to reducing risk. This article briefly introduces OSHA’s approach and the benefits of implementing an energy control program. A more detailed explanation of OSHA's LOTO standard can be found on our OSHA Lockout Tagout Standard page.

What is OSHA Lockout Tagout?

OSHA Lockout Tagout refers to a safety standard (29 CFR 1910.147) that requires employers to isolate and control hazardous energy sources during equipment servicing to prevent unexpected startup or energy release that could cause serious worker injuries.

The Occupational Safety and Health Administration (OSHA) requires that both the authorized employee, who performs lockout/tagout procedures, and the affected employee, who operates or works near the machinery and equipment being serviced, understand their roles in hazardous energy control. OSHA mandates the control of hazardous energy by the use of proper energy isolating devices and lockout devices to prevent unexpected startup of machines or equipment during maintenance. By ensuring each employee knows how to apply and respect these safety measures, organizations reduce the risk of injury and maintain full compliance with federal energy control standards.

OSHA’s Purpose Behind the Lockout Tagout Rule

The primary objective of the LOTO standard is to prevent injuries caused by the unexpected energization or startup of machines. Before the regulation was enacted, workers routinely suffered amputations, electrocutions, burns, and crushing injuries due to uncontrolled energy sources during servicing activities.

OSHA recognized the need for a national standard that would require employers to implement:

Clear procedures for de-energizing and equipment servicing
Proper use of lockout/tagout devices
Employee training and role definition
Periodic inspections to ensure compliance

The standard applies to most general industry workplaces and covers all forms of hazardous energy: electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and gravitational.

Workplace Accident Statistics

LOTO was created in response to alarming injury rates. According to data from OSHA and the U.S. Bureau of Labor Statistics:

Approximately 10% of serious electrical injuries are due to inadequate or missing LOTO procedures.
Each year, about 120 workers die from hazardous energy incidents that could have been prevented.
OSHA estimates that compliance with its LOTO standard prevents over 50,000 injuries and saves more than 100 lives annually.

These figures highlight the severity of the risk and the proven effectiveness of OSHA’s regulation in reducing preventable harm.

Why Lockout Tagout Matters

LOTO isn’t just a compliance checkbox—it’s a life-saving practice. Anytime an employee services or maintains machinery, there is a risk that the equipment could move unexpectedly or release stored energy. Without effective energy isolation, a routine task like clearing a jam or tightening a bolt can become fatal.

Common hazards include:

Machines restarting while a worker’s hands or tools are inside
Pneumatic lines discharging compressed air without warning
Hydraulic pressure suddenly moving pistons or clamps
Electrical circuits being re-energized mid-repair

LOTO procedures are designed to prevent these incidents by ensuring all energy sources are de-energized, locked in place, and clearly labeled before work begins.

OSHA’s Compliance Goals

The Lockout Tagout standard is built on a structured approach to safety. OSHA’s goal is to create a consistent, enforceable framework that:

Identifies and isolates energy sources using approved devices
Defines employee responsibilities (authorized, affected, and other workers)
Requires written procedures for equipment with more than one energy source
Mandates training and retraining to ensure awareness and skill retention
Requires periodic audits of LOTO programs and procedures

Employers are expected to document and implement a complete energy control program, supported by internal procedures, training, inspections, and recordkeeping.