What LOTO Devices Are Used in Manufacturing Facilities?

Key Takeaways

• LOTO devices are safety tools that isolate hazardous energy sources, preventing accidental machine activation during maintenance or servicing.

• Valve lockouts, plug lockouts, group lockout boxes, and circuit breaker lockouts are widely used in manufacturing for controlling hazardous energy.

• Lockout tagout procedures do not slow operations but reduce downtime by preventing accidents and streamlining maintenance processes.

• Digitized lockout tagout systems enhance safety with real-time monitoring, automated records, and remote access to procedures.

 

Why Is Lockout Tagout (LOTO) Crucial in Manufacturing?

If you’ve ever worked in a manufacturing facility, you know the safety risks of maintaining or servicing equipment. From moving machine parts to electrical energy surges, there’s a lot that can go wrong if hazardous energy isn’t controlled.

In 2023, the Bureau of Labor Statistics (BLS) reported that around 2 out of every 100 full-time workers in the manufacturing industry are at risk of work-related injuries and illnesses. The industry also accounted for 5,283 work-related fatalities in the same year. These statistics highlight the urgent need for industries to prioritize workplace safety by enforcing robust safety protocols to prevent accidents.

Among the top 10 most frequently cited Occupational Safety and Health Administration (OSHA) standards in 2023 was 29 CFR 1910.147, "The Control of Hazardous Energy (Lockout/Tagout)." This is a clear indication that many companies are still failing in this critical area. Non-compliance not only increases safety risks but also exposes organizations to steep OSHA fines and penalties.

One straightforward yet impactful step companies can take is to implement or enhance the use of OSHA-compliant lockout tagout (LOTO) devices. These devices significantly safeguard workers by ensuring proper hazardous energy control during maintenance and servicing activities.

 

What Are LOTO Devices?

LOTO devices are tools specifically designed to physically block hazardous energy sources, such as electrical, mechanical, hydraulic, pneumatic, chemical, or thermal energy, in machines and equipment. They serve as a protective barrier, isolating energy sources to safeguard workers from potential dangers. By deactivating energy flow, they prevent accidental or unauthorized reactivation during maintenance or repair work, reducing the risk of injuries.

Proper use of lockout tagout devices contributes significantly to workplace safety and operational reliability. They help reduce accidents such as electrical shocks, unexpected mechanical movements, or the sudden release of fluids and gases. Moreover, they establish clear and secure procedures for isolating machinery, supporting compliance with OSHA safety standards and seamless maintenance processes.

 

4 Types of LOTO Devices

There are various types of LOTO devices, each designed for specific applications and machinery. Choosing the right one depends on the equipment, the type of hazardous energy involved, and the environment. Below are four commonly used types of devices across the manufacturing industry:

Valve Lockout Tagout

These devices are used to secure valves and block the flow of liquids, gases, or other substances. They are compatible with different valve types, such as ball valves and gate valves, and are essential for industries involving fluid systems, such as manufacturing, chemical plants, and oil refineries. Valve lockout tagout devices are essential for maintaining worker safety when dealing with pressurized systems or hazardous materials.

• • Ball Valve Lockouts: Locks the handle of ball valves in the "off" position to prevent fluid or gas flow.

  • Butterfly Valve Lockouts: Clamps around the lever of butterfly valves, restricting movement to keep it securely locked.

  • Gate Valve Lockouts: Encloses the handwheel of gate valves to prevent turning and accidental release of stored energy.

Electrical Plug Lockout Tagout

These are designed to block access to electrical plugs, preventing unauthorized use of portable machines or tools by encasing or blocking the plug to stop it from being connected to a power source. Electrical plug lockout tagout devices are ideal for equipment powered by standard electrical outlets and are frequently used in workshops, factories, and construction sites. 

• • Plug Lockouts: Securely encase electrical plugs to block connection to power outlets.

  • Socket Lockouts: Lock over electrical sockets to block access and prevent unauthorized use of the outlet.

Group Lockout Tagout

Group lockout tagout is when multiple workers are involved in maintaining or servicing the same piece of equipment. It allows each worker to apply their own lock to a group lockout box or hasp, ensuring no one can reactivate the energy source until all workers have completed their tasks and removed their locks. This method adds an extra layer of safety and accountability in shared work environments.

• • LOTO Boxes: Securely store keys for multiple lockout devices in a central, locked container for group activities.

  • Lockout Hasps: Allow multiple workers to apply personal locks to a single energy isolation point.

  • Cable Lockout Device: Flexible cables that can secure multiple energy sources, such as valves or circuit breakers, at once.

Electrical Panel Lockout Tagout

These devices are designed to restrict access to circuit breakers, miniature circuit breakers (MCBs), and electrical panels during maintenance or repairs. The image above shows a large breaker lock securing a circuit breaker for maintenance activities. In other cases, individual breaker locks or full panel covers are used to prevent accidental reactivation of electrical systems. These breaker locks are particularly important for protecting workers from electrical hazards while servicing equipment connected to the panel.

• • Circuit Breaker Lockouts: Attach to individual circuit breakers, blocking them from being flipped back on.

In addition to primary lockout tagout devices, tools such as personal padlocks and emergency push button lockout devices provide added safety for a variety of applications.

Lockout tagout padlocks are used to secure lockout tagout (LOTO) devices in place, offering a physical and visual deterrent to accidental energy reactivation. Push button lockout devices are designed to block access to control buttons, switches, or levers, adding another layer of protection during servicing or repairs. These supplementary devices enhance the overall lockout tagout procedure by addressing specific needs across different equipment types.

 

When to Use Lockout Tagout Devices?

LOTO devices are necessary whenever there is a risk of exposure to hazardous energy during servicing or maintenance. This includes situations involving:

1. Tasks requiring disassembly, cleaning, repair, or maintenance of equipment.
2. Tasks requiring the moving of machines or equipment.
3. Tasks requiring the testing of machines or equipment.

Applying the devices alone is not enough; the authorized employee must perform an isolation verification to confirm that the energy sources are completely isolated and cannot be reactivated. To verify this, employees can ask themselves the following questions:

1. Have all energy sources connected to the equipment been properly identified?

2. Are the correct lockout tagout devices applied securely to each energy source?

3. Has all residual energy been discharged or released?

4. Have I attempted to activate the machine using its controls to confirm it is fully de-energized?

5. Is the equipment visually inspected to ensure there is no movement or power to any components?

 

Benefits of Using LOTO Devices in Manufacturing

There’s a common misconception that lockout tagout procedures slow down operations, but this belief often arises from a lack of understanding about their importance and long-term benefits. This includes:

• • Preventing injuries and fatalities caused by unexpected startup of machinery.

  • Protecting employees from exposure to hazardous energy.

  • Reducing the risks of equipment damage.

  • Ensuring that only authorized personnel can start up the machine.

  • Enhancing compliance with OSHA standards.

 

LOTO Examples in Manufacturing

In April 2024, a 26-year-old employee at an automotive parts manufacturer in Franklin, Ohio, was fatally crushed while placing cardboard under a machine used for bending vehicle exhaust pipes. OSHA’s investigation found the company failed to provide proper machine guarding, lacked detailed lockout tagout procedures, and did not conduct annual safety tests. These lapses exposed workers to hazardous conditions, leading to 10 citations and $314,555 in penalties.

If LOTO procedures had been in place, the machine would have been fully de-energized before maintenance. The authorized employee would have identified energy sources, applied appropriate lockout tagout (LOTO) devices, and verified the lockout equipment’s safety. These steps could have prevented the accident, highlighting the importance of robust LOTO protocols for worker safety.

 

Criteria for Choosing the Right LOTO Devices for Specific Applications

OSHA's Device Requirements

According to OSHA 1910.147(c)(5)(i), employers should provide locks, adapter pins, wedges, and other hardware necessary for protecting employees from hazardous energy sources.

OSHA has specific requirements for LOTO tools allowed in a hazardous workplace. It is essential to ensure that the devices you choose meet these requirements as stated under the subsections of OSHA 1910.147(c)(5)(ii):

• • DURABLE: Lockout tagout devices should be durable enough to withstand harsh industrial environments. These devices must not deteriorate when exposed to corrosive components for the maximum period of time that exposure is expected.

  • STANDARDIZED: LOTO devices should be standardized within the facility in at least one of these criteria: size, shape, and/or color. As for tagout devices, the print and format should also be standardized.

  • SUBSTANTIAL: Lockout devices should be substantial enough to prevent removal without the use of excessive force or the use of metal-cutting tools. Tagout devices should be substantial enough to prevent inadvertent or accidental removal. Attachment means that tagout devices should be non-reusable, attachable by hand, self-locking, and non-releasable with a minimum of no less than 50 pounds of unlocking strength.

  • IDENTIFIABLE: LOTO devices should indicate the identity of the worker applying the device(s) on the machine or equipment.

OSHA also requires that all padlocks used in a LOTO program have a distinct shape and color that fits the environment. While OSHA did not specify colors for LOTO devices and tags, they recommend this color coding scheme as follows:

• • DANGER: Red, or predominantly red, with lettering or symbols in a contrasting color.

  • CAUTION: Yellow, or predominantly yellow, with lettering or symbols in a contrasting color.

  • WARNING: Orange, predominantly orange, with lettering or symbols in a contrasting color.

  • BIOLOGICAL HAZARD: Fluorescent orange or orange-red, or predominantly so, with lettering or symbols in a contrasting color.

Industrial Environment

In choosing the right energy isolating device, you should also consider the environment in which the machine or equipment is used. For instance, machines/equipment used outdoors may require locks, tags, or other lockout tagout devices that are waterproof and weatherproof. Machinery used in a dirty or oily environment may require locks or tags that can be cleaned easily.

Kind of Machinery or Equipment

Not all machinery and equipment in a manufacturing facility need to be locked out. According to OSHA, controlling hazardous energy (lockout/tagout) procedures apply to machines and equipment wherein unexpected energization could harm employees.

The type of machine or equipment being locked out determines the appropriate energy-isolating device required. For instance, locking out a gas valve would require a valve lockout device along with a padlock or similar locking mechanism to secure it.

Types of Hazardous Energy in the Facility

Each type of hazardous energy has specific requirements for lockout tagout devices. For instance, dangerous electrical energy requires lightweight locks or tags that can be used to lock small circuit breakers and electrical switches because heavy padlocks can damage them. LOTO devices made of durable plastic materials are also ideal for locking out electrical energy sources because they are non-conductive.

The following are some of the hazardous energy that may be released in a manufacturing facility:

• • Electrical energy: This includes high and low voltage, current, and sparks.

  • Mechanical energy: This is the energy released by rotating or moving parts.

  • Chemical energy: This includes flammable and combustible vapors, liquids, and solids.

  • Thermal energy: This includes fires, explosions, and heat sources.

  • Pneumatic potential energy: This includes compressed gasses and liquids.

  • Radiation energy: This includes microwaves, x-rays, and gamma rays.

 

What Is Required on a Machine Specific LOTO Procedure?

Machine specific LOTO procedures are detailed guidelines tailored to individual equipment, focusing on its unique energy sources and associated hazards. Its key components include identifying all energy sources tied to the machine, specifying the lockout points and how lockout tagout devices should be applied, and providing instructions for safely verifying that the equipment is properly shut. The safety procedure also includes steps for re-energizing the equipment once the maintenance is complete.

By addressing the specific risks and complexities of each piece of equipment, a machine specific lockout tagout procedure serves as an essential tool for maintaining safety and compliance in manufacturing environments.

 

Digitized Lockout Tagout in Manufacturing

As manufacturing progresses toward digitization, digitized lockout tagout integration continues to roll out. These systems allow workers to access machine-specific procedures instantly on digital devices, reducing reliance on paper-based methods. Automated documentation tracks LOTO applications, creating detailed audit trails for compliance and accountability.

Additionally, remote access enables supervisors to monitor and manage lockout tagout (LOTO) procedures across multiple facilities, streamlining operations and enhancing workplace LOTO safety practices.

 

LOTO Devices FAQs

What are isolating devices?

Isolating devices are mechanical or electrical components used to disconnect equipment from its energy source, preventing the accidental release of hazardous energy. Examples include circuit breakers, valves, and switches that can be locked in the "off" or "closed" position during maintenance.

What is the first step when applying lockout devices?

The first step is to identify all energy sources connected to the equipment, including primary and secondary sources such as electrical, hydraulic, or pneumatic energy. This helps ensure that all potential hazards are accounted for before proceeding with the lockout process.

Do lockout devices have to be red in color?

No, lockout devices are not required to be red, but they must be durable, standardized, and easily recognizable. Many companies use red as a common color for visibility, but OSHA does not mandate a specific color.

Can tagout devices replace lockout devices?

Tagout devices can only replace lockout devices when applying a lockout device physically is impossible, and additional safety measures are implemented. However, lockout devices are generally preferred because they provide a more secure method of isolating energy sources.

What equipment is required for safe isolation?

Safe isolation requires lockout devices like padlocks, valve lockouts, circuit breaker lockouts, and cable lockouts, as well as tagout devices for labeling purposes. Additional tools, such as multimeters for energy verification, may also be needed to confirm the absence of residual energy.