How to Use LOTOTO Procedure

Ensuring the safety of workers during maintenance or servicing of machinery is a critical responsibility in any industrial setting. One of the most effective safety practices is the LOTOTO procedure—an acronym for Lock Out, Tag Out, Try Out. This procedure prevents accidental energization of machinery, protecting employees from serious injuries. This guide explains how to correctly implement the LOTOTO procedure.

1. Understand the LOTOTO Procedure

LOTOTO is designed to control hazardous energy sources during maintenance. It involves three key steps:

Lock Out (LO): Physically isolate the energy source by using locks to prevent machinery from being powered on.
Tag Out (TO): Place warning tags to indicate that the machine is under maintenance and must not be operated.
Try Out (TO): Test the system to ensure that energy has been fully isolated and the equipment cannot start unexpectedly.

By following these steps, you can effectively reduce the risk of injuries caused by unexpected startup, release of stored energy, or electrical hazards.

2. Prepare Before Locking Out Equipment

Before initiating the LOTOTO procedure, it’s important to:

Identify all energy sources: Check for electrical, mechanical, hydraulic, pneumatic, chemical, or thermal energy sources.
Notify affected personnel: Inform everyone in the area about the maintenance schedule and that the equipment will be locked out.
Understand the equipment: Review operation manuals and safety procedures to understand the isolation points.

Preparation ensures that no energy source is overlooked, and all workers are aware of the maintenance activities.

3. Lock Out Procedure

Turn off the equipment: Switch the machine to the “OFF” position according to standard operating procedures.
Isolate energy sources: Close valves, disconnect power, or block mechanical parts to stop energy flow.
Apply locks: Attach lock devices to switches, valves, or other control points to prevent accidental reactivation.
Verify locks are secure: Ensure the locks cannot be removed without proper authorization.

Locks must be durable, standardized, and clearly labeled to prevent accidental removal or tampering.

4. Tag Out Procedure

Attach warning tags: Place tags on all energy isolation points. Tags should indicate the reason for the lockout, the person responsible, and the expected maintenance duration.
Communicate the lockout: Ensure all personnel recognize that the equipment is tagged and must not be operated.
Check compliance: Supervisors should confirm that tags are visible and legible to everyone in the area.

Tags act as a visual warning and communicate that machinery is unsafe to operate until maintenance is complete.

5. Try Out Procedure

Test for isolation: Attempt to operate the machine using normal controls to ensure that it cannot start.
Verify energy sources are neutralized: Confirm that no mechanical, electrical, or stored energy remains.
Double-check safety: Only when the machine is fully de-energized should maintenance begin.

The Try Out step ensures that the Lock Out and Tag Out measures are effective, giving workers confidence that the equipment is safe.

6. Completing the LOTOTO Procedure

After maintenance is complete:

Remove tools and replace guards: Ensure the machine is restored to its original configuration.
Remove tags and locks: Only the person who applied the lock/tag should remove it.
Notify personnel: Inform everyone that maintenance is complete and equipment is operational.
Test the machine safely: Perform a controlled startup to ensure everything functions correctly.

Following these steps prevents premature energization and ensures a smooth transition back to normal operation.

7. Key Safety Tips

Always follow company-specific LOTOTO policies.
Never bypass locks or tags.
Only trained and authorized personnel should perform LOTOTO procedures.
Maintain a log of all lockout/tagout activities for accountability and compliance.