OSHA Compliance
Lockout/Tagout (LOTO) Procedure Template — OSHA 29 CFR 1910.147
A free lockout/tagout written program and machine-specific procedure template for OSHA 29 CFR 1910.147. Covers all required program elements, the 7-step isolation sequence, training requirements, and annual inspection certification — with a filled-in example from a CNC machine shop.
Free Lockout/Tagout Procedure Template
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Download Blank TemplateWorked Example — ABC Precision Manufacturing
Download ExampleWhy LOTO Is OSHA's #4 Most Cited Violation
Lockout/tagout violations consistently rank in OSHA's top five most-cited standards — and in manufacturing, LOTO-related incidents are among the most severe. The standard addresses a simple, preventable scenario: a worker is performing maintenance or clearing a jam when another employee inadvertently restarts the machine.
OSHA's 29 CFR 1910.147 (The Control of Hazardous Energy) applies to general industry employers whose employees service or maintain equipment where unexpected energization, startup, or release of stored energy could cause injury. In a manufacturing environment, this means virtually every piece of powered equipment — CNC machines, conveyors, presses, air-powered tools, and hydraulic equipment all qualify.
The standard has three layers: a written energy control program (facility-wide policy), machine-specific energy control procedures (one per piece of equipment), and training for employees in each category. All three are required, and a citation on any one of them is a separate violation.
The Three Layers of a Compliant LOTO Program
Written Energy Control Program
The facility-level policy document. It must describe the scope, purpose, and rules for the program — including how the employer intends to comply with each section of 1910.147. This is often a single 3–5 page document. OSHA inspectors ask to see this first.
Machine-Specific Energy Control Procedures
A separate written procedure for each machine or piece of equipment. Must identify the type and location of every energy source, the sequence of steps to isolate and control energy, the hardware required (lock type, hasp, blocking device), and the steps to restore energy after work is complete.
Employee Training by Category
Three training categories: authorized employees (who perform the lockout), affected employees (who work in the area), and other employees (everyone else in the facility). Each category has different required content. Training records must be retained and retraining conducted when procedures change or deficiencies are observed.
The 7-Step LOTO Sequence
Every machine-specific LOTO procedure must document the correct sequence for applying and removing energy controls. OSHA does not mandate a specific format, but the procedure must be clear enough that any authorized employee can follow it correctly. Here are the seven steps the template covers:
Notify Affected Employees
Before beginning any LOTO procedure, notify all affected employees that the equipment is being shut down and locked out. Affected employees are those who operate the equipment or work in the area. They must know not to attempt to restart the machine until the lockout is removed.
Identify All Energy Sources
Identify all energy sources associated with the equipment: electrical, pneumatic, hydraulic, mechanical (gravity, springs), thermal, and chemical. The machine-specific procedure must list every energy source by type and location. Failure to identify secondary or stored energy sources is a leading cause of LOTO-related injuries.
Shut Down the Equipment
Shut down the equipment using the normal stopping procedure. Do not proceed to lockout from a running state if a controlled shutdown is possible. Note that shutdown is not the same as lockout — the machine must be fully de-energized and all stored energy released before lockout is applied.
Isolate All Energy Sources
Operate all energy-isolating devices to the safe (off) position. This includes disconnecting electrical circuits at the disconnect switch (not just at the control panel), closing pneumatic/hydraulic supply valves, and blocking or restraining any mechanical parts subject to gravity or spring tension. Each isolating device must be physically moved to the de-energized position.
Apply Lockout/Tagout Devices
Apply a personal lock to each energy-isolating device. Each authorized employee working on the equipment must apply their own lock — one person, one lock. If multiple people are working, each person applies their own lock to the lockout hasp. Tags are added as required by your program. The machine cannot be re-energized while any lock remains in place.
Release or Restrain Stored Energy
Dissipate or restrain all residual stored energy before work begins. This includes bleeding pneumatic/hydraulic lines, discharging capacitors, blocking elevated machine parts that could fall under gravity, releasing spring tension, and allowing thermal energy to dissipate. Stored energy is one of the most commonly overlooked hazards in LOTO procedures.
Verify Isolation
Before starting work, verify that the equipment has been fully de-energized and all energy sources controlled. Attempt to operate the normal start or "on" controls to verify the machine will not energize. Return controls to the "off" position after verification. This verification step is required and must be performed before any employee begins work on the equipment.
Filled-In Example: ABC Precision Manufacturing
Below is an excerpt from the LOTO program at ABC Precision Manufacturing — a 28-employee CNC machine shop. This example shows a machine-specific energy control procedure for their Mazak Integrex i-400 multi-tasking machine.
MACHINE-SPECIFIC ENERGY CONTROL PROCEDURE
ABC Precision Manufacturing, LLC | Procedure No. LOTO-007 | Rev A
Equipment: Mazak Integrex i-400 | Area: CNC Cell 2 | Effective: February 1, 2026
Equipment Information
Energy Source Inventory
| Energy Type | Location / Description | Magnitude | Isolation Method | Lock Point |
|---|---|---|---|---|
| Electrical (main) | Main disconnect — left side of machine, gray panel | 480V / 3-phase | Rotate to OFF, apply lock | Lock Point E-1 (red tag) |
| Electrical (control) | Control panel disconnect — rear of machine | 120V | Rotate to OFF, apply lock | Lock Point E-2 |
| Pneumatic | Air supply ball valve — rear lower left | 90 PSI | Turn to closed (perpendicular), bleed line | Lock Point P-1 (valve lockout) |
| Hydraulic | Hydraulic power unit — rear right | 1500 PSI | Isolate via shutoff valve, bleed pressure at test port | Lock Point H-1 |
| Gravity (chuck jaws) | Spindle chuck — stored tension in jaws | N/A | Open jaws fully before shutdown, block spindle if needed | Verify visually |
Shutdown & Lockout Sequence
- Notify affected employees (CNC Cell 2 team) that machine is being locked out.
- Bring machine to a controlled stop using the E-stop or normal cycle-end procedure.
- Open chuck jaws fully and verify no workpiece is loaded.
- Close hydraulic shutoff valve (Lock Point H-1). Bleed residual pressure at rear test port. Verify gauge reads 0 PSI.
- Close pneumatic ball valve (Lock Point P-1) and bleed downstream lines by cycling air-blow valve. Verify 0 PSI.
- Turn control panel disconnect to OFF and apply personal lock (Lock Point E-2).
- Turn main 480V disconnect to OFF and apply personal lock (Lock Point E-1).
- Attempt to start machine using normal start button — verify no response.
- Begin work.
Annual Inspection Certification
| Inspection Date | Inspector (Auth. Employee) | Employees Involved | Findings | Corrective Actions |
|---|---|---|---|---|
| Feb 5, 2026 | Maria Gonzalez | J. Torres, D. Kim | Procedure accurate. D. Kim unfamiliar with hydraulic bleed step — retraining conducted. | D. Kim retrained Feb 5, 2026. Record on file. |
Common LOTO Violations — and How to Avoid Them
| Violation | Why It Happens | How to Prevent It |
|---|---|---|
| No written energy control program | Employer relies on informal practice or verbal instructions | Create the facility-level program document. OSHA inspectors ask for this first — if it does not exist, citations follow for every machine. |
| Generic procedure used for all machines | Employer writes one universal LOTO procedure rather than machine-specific ones | Write a separate procedure for each machine. Post it at the machine or keep in a binder at the work cell. |
| Stored energy not addressed | Procedure covers electrical but misses pneumatic, hydraulic, or gravity energy | Walk down each machine and identify all energy sources — including secondary sources. Have a qualified maintenance technician review each machine procedure. |
| Annual inspection not performed or not certified | Inspection happens informally but no written certification is produced | Schedule annual LOTO procedure inspections as a recurring calendar event. Use the certification form in the template — OSHA requires written certification with specific fields. |
| Authorized employee performs lockout without their own lock | "Group lockout" relies on one supervisor lock rather than individual locks | One person, one lock. Provide each authorized employee with a personal lock and tag. Group lockouts require a hasp with multiple lock points. |
| No training records for affected or other employees | Authorized employee training is documented but affected/other employee training is not | Train all three categories and retain records for each. OSHA can cite training deficiencies for any category independently. |
Track LOTO Training in Training Tiger
OSHA requires training records for all three LOTO employee categories — authorized, affected, and other — plus retraining records whenever procedures change or deficiencies are found. Training Tiger keeps those records audit-ready: assign training by role, track completion, and automatically trigger retraining when your LOTO procedure document is revised.
- →Assign LOTO training by role — authorized employees vs. affected employees vs. general workforce
- →Store LOTO procedure documents with version control and approval workflow
- →Automatic retraining triggers when a LOTO procedure is revised
- →Exportable training records with timestamps and sign-offs for OSHA inspection
Frequently Asked Questions
What does OSHA 29 CFR 1910.147 require for lockout/tagout?
OSHA 29 CFR 1910.147 requires a written energy control program, machine-specific LOTO procedures for each piece of equipment where unexpected energization could cause injury, employee training by category (authorized, affected, other), and annual periodic inspections of each energy control procedure certified in writing.
Do you need a separate LOTO procedure for every machine?
Yes, in most cases. OSHA requires a written procedure for each machine where an employee could be exposed to unexpected energization. A single generic procedure does not satisfy the requirement. The narrow exception — single, clearly visible energy source locked out with one device — rarely applies in manufacturing environments.
How often must LOTO procedures be inspected under OSHA?
At least annually. The inspection must be performed by an authorized employee other than the one who uses the procedure, and must be certified in writing with the machine name, inspection date, employees involved, and the inspector's name. This certification is commonly missed and is a frequent OSHA citation.
What is the difference between lockout and tagout?
Lockout uses a physical lock to prevent re-energization. Tagout uses a warning tag when a lock cannot be applied. OSHA requires lockout wherever equipment is capable of being locked out. Tagout-only programs require additional protective measures and are only permitted when equipment cannot physically accept a lock.
What training is required for LOTO under OSHA 1910.147?
Three categories: (1) Authorized employees — those performing the lockout — must be trained on hazardous energy recognition, types and magnitude in the workplace, and control methods. (2) Affected employees must be trained on the program purpose and the prohibition on restarting locked-out equipment. (3) All other employees in the area must know LOTO procedures exist and not to touch locked-out equipment. Retraining is required when procedures change or inspections reveal deficiencies.