What Are the Steps of Lockout/Tagout?

Prepare by identifying the machine, hazards, and procedure. Notify affected workers. Shut down normally. Isolate each energy source. Apply personal locks and tags. Release or restrain stored energy. OSHA lists six steps in this order: prepare, shut down, isolate, apply locks and tags, control stored energy, and verify.

Verify isolation using the approved try-start, test, gauge, or other method. Return controls to a safe position after the check. Only then may authorized service begin.

Verification must test the energy that could hurt the worker. A zero pressure gauge is useful only when the gauge and connection work. A try-start checks the control circuit but may not prove a gravity gate is blocked. Match the test to each hazard.

After work, inspect the machine, replace guards, account for workers, remove tools, and notify affected staff. Each authorized worker removes their own lock, except under the formal exception process. Restore energy in the approved order.

Watch the first controlled startup after maintenance. Confirm workers are clear, valves are correct, guards are installed, and the process can accept flow. An unexpected sound, leak, vibration, or alarm is a reason to stop and reassess rather than assume the repair needs time to settle.