Lockout Tagout: Pros, Cons, & How to Get Your Crew On Board
Things can go south fast on a job site, especially when equipment fails without warning. Productivity tanks. Workers stand around waiting. And worst of all? If safety procedures aren’t in place, someone could get seriously hurt.
Do you have a plan to protect your crew and prevent costly downtime? If Lockout/Tagout (LOTO) isn’t part of it, it’s time to rethink your safety strategy.
What is Lockout Tagout (LOTO) & Why Does It Matter?
Lockout Tagout (LOTO) is a vital safety procedure that means the equipment’s hazardous energy release is shut off and cannot be restarted before maintenance or repair work is completed. The procedure involves isolating hazardous energy sources and rendering them inoperative. Lockout tagout is crucial for preventing accidental startups and protecting workers from potentially hazardous energy.
Here’s how it works:
- Isolate – All hazardous energy sources must be isolated, with machinery confirmed “dead”.
- Lock Out – Once the machine’s energy source is isolated, it is locked out, preventing energy from being restored.
- Tag Out – A warning tag is attached to the lock to identify the worker responsible and the reason for the lockout during equipment maintenance. It is also a good idea to identify when the job is expected to be completed.
- Try Out—It is important to try turning on the machinery to make sure all energy sources have been isolated and the lockout is effective at preventing the equipment from being restarted. This will also release any stored energy that can be hazardous.
The key to the lock is held by the worker, making sure that only they can remove the lock and restart the equipment when the job is done. LOTO isn’t just about following rules—it’s about saving lives. Every year, hundreds of workers suffer injuries due to unexpected equipment startups. A solid LOTO procedure eliminates that risk.
The Pros of Lockout Tagout Devices
Protects Your Crew
LOTO is all about safety. Machines don’t care if someone’s in the way when they suddenly power back on. LOTO prevents accidents before they happen by ensuring equipment remains off until the job is complete.
Keeps You OSHA Compliant
LOTO isn’t optional; it’s required. Not following LOTO procedures isn’t just dangerous—it’s expensive. OSHA fines can reach thousands of dollars per violation, increasing liability risks and putting your company on the radar for future inspections.
Prevents Equipment Downtime & Damage
If equipment powers up mid-repair, you’re not just looking at safety risks—you’re looking at thousands in potential damages to your machines and extended repair times. LOTO keeps your machines and schedule intact.
TireSocks’ Lockout Tagout Products Make It Easy
Having the right LOTO tools matters. TireSocks offers durable LOTO solutions, from padlocks and hasps to adjustable cable lockouts and high-visibility tags—everything your crew needs for an effective lockout.
Lockout Tagout Cons (And How to Overcome Them)
Even with its benefits, some crews push back on LOTO. Here are the biggest complaints and how to fix them.
Takes Time to Set Up
LOTO requires training and preparation—but so do hospital visits and OSHA investigations.
Solution: Make LOTO part of your routine safety meetings and invest in user-friendly LOTO devices that speed up the process.
It’s Easy to Forget or Skip
If LOTO isn’t followed correctly, it’s as good as not having it at all.
Solution: Implement clear, documented procedures and high-visibility tags and locks. Assign specific accountability to make sure everyone follows through.
The Crew Sees It as a Hassle
Some teams get used to cutting corners to save time, but that mindset can lead to serious injuries.
Solution: Show them real-world accident stats and how OSHA fines could hit their paychecks. Make LOTO easier by using the right products and reinforcing training.
Common Lockout Tagout Violations
Still not convinced? These are the most common LOTO failures that lead to OSHA citations, injuries, and downtime:
- No formal LOTO program or training
- Not isolating hazardous energy sources properly
- Using locks and tags incorrectly
- Skipping regular LOTO inspections and audits
These mistakes can lead to injuries, fines, and delays, so having a well-documented and enforced LOTO system is crucial. Don’t wait until you’re facing penalties—or worse, an injury—to take action. A solid LOTO program keeps your team safe and your job site running smoothly.
Lockout Tagout FAQs
What’s the difference between Lockout and Tagout?
- Lockout physically prevents equipment from being turned on by locking energy-isolating devices.
- Tagout is a visual warning system that tells workers not to use the equipment, but does not physically prevent operation.
- Both should be used together for maximum safety.
Is LOTO required on all job sites?
Yes, if there’s a risk of hazardous energy release during maintenance, OSHA requires LOTO compliance. This applies to construction, manufacturing, and industrial sites.
What are the best LOTO products for my crew?
Having the right LOTO tools makes compliance fast and foolproof. Here’s what we recommend—along with how to decide which products work best based on your environment, the way your crew operates, and the kind of equipment you’re locking out:
- Safety Padlocks – Used for individual machine lockouts. TireSocks offers two types that are both tough, secure, and built for job-site conditions:
- Aluminum Safety Padlocks (Red or Blue): Lightweight but extremely durable with a corrosion-resistant aluminum body. They’re great for harsh, outdoor, or chemical-heavy environments. Key retention prevents keys from being removed when the lock is open.
- Nylon Safety Padlocks: Non-conductive nylon body and steel shackle. These are lighter, ideal for indoor use, and especially suited for electrical work. Keyed differently for added safety, they include etched keys and standard labeling.
- Which to choose? If your crew is working in outdoor or chemical-heavy environments and needs something built to last, go with Aluminum padlocks. If you need a non-conductive, lightweight solution for everyday or electrical use, choose Nylon padlocks.
- Steel Lockout Hasp – For group lockouts where multiple workers need to lock the same energy source.
- Cable Lockouts– Flexible, adjustable, and ideal for irregularly shaped or hard-to-reach power sources like valves and panel switches.
- Group Lockout Box – Keeps multiple padlocks and keys secure during group LOTO procedures. Especially useful for larger jobs or interlock systems.
- Forklift Lockout Kit – A complete, all-in-one solution designed to safely lock out forklifts during inspection, maintenance, or repair.
- High-Visibility Warnings: Do Not Operate Tuff Tags – OSHA-compliant tags that clearly indicate the equipment is off-limits. Reinforced and designed to stand up to job site wear and tear.
How do I get my team to follow LOTO correctly?
- Hold regular training to reinforce proper LOTO procedures.
- Use standardized LOTO devices so every worker follows the same system.
- Audit compliance regularly to find gaps and improve procedures.
Final Thoughts on LOTO Safety
LOTO is more than a checklist—it’s a job site lifesaver. With the right products and procedures in place, your crew stays safe, your projects stay on track, and your company stays compliant.
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