Key OSHA Requirements for Lockout Tagout and How to Stay Compliant

by | Aug 28, 2025 | Safety Signs

Lockout Tagout (LOTO) is one of the most important workplace safety practices for preventing injuries caused by the unexpected startup of machinery. OSHA has specific requirements for LOTO, and understanding them is essential for keeping your workplace safe and compliant.  

How to Stay OSHA Compliant for Your Lockout Tagout Program

Let’s break down the key OSHA compliance Lockout Tagout requirements and explore how your facility can meet them effectively.

1. Develop a Written LOTO Program

OSHA requires every employer to have a written Lockout Tagout program that outlines the steps to control hazardous energy. This document should clearly explain who is authorized to perform LOTO, when the procedure must be used, and the exact process for shutting down, isolating, and securing equipment.

A well-written program serves as a reference guide for employees and ensures that everyone follows the same safety standards. Keep this document accessible and update it whenever new equipment or processes are introduced.

2. Identify All Sources of Hazardous Energy

It’s not enough to lock out the main power switch—OSHA requires facilities to identify all potential energy sources. This includes electrical, mechanical, hydraulic, pneumatic, chemical, and thermal energy.

Perform a thorough energy survey of each piece of equipment. By documenting every potential hazard, you can ensure that your LOTO procedures fully address the risks and reduce the chance of accidents caused by overlooked energy sources.

3. Provide Proper Training for Employees

OSHA mandates training for three categories of workers:

  • Authorized employees who perform lockout and tagout.
  • Affected employees who operate or work near locked-out equipment.
  • Other employees who need to understand LOTO for general safety awareness.

Training should cover the purpose of LOTO, step-by-step procedures, and the importance of following the rules. Refresher sessions are also necessary to keep safety knowledge fresh and up to date.

4. Use the Right Lockout and Tagout Devices

Compliance isn’t just about procedure—it’s also about using the right tools. OSHA requires durable, standardized locks and tags that are easily recognizable and resistant to removal without the key or a designated tool.

Locks must be assigned to a single employee, ensuring accountability, while tags should clearly display information about the person responsible for the lockout. Using high-quality, OSHA-approved devices helps prevent accidental removals and enhances safety.

5. Conduct Regular Inspections

OSHA requires periodic inspections—at least annually—of your LOTO procedures. These inspections verify that employees are following the process correctly and that the program remains effective.

During an inspection, a qualified person should observe the lockout steps, review the equipment list, and confirm that all required training has been completed. Any issues found should be addressed immediately to prevent compliance gaps.

Conclusion: How to Stay OSHA Compliant for Your Lockout Tagout Program

Following OSHA’s Lockout Tagout requirements isn’t just about avoiding fines—it’s about keeping workers safe from life-threatening hazards. By creating a detailed written program, identifying all energy sources, providing proper training, using the right devices, and performing regular inspections, you can build a strong safety culture and stay fully compliant. In the end, compliance not only protects your people but also strengthens the long-term success of your operations.