Protect Your Employees With OSHA-Certified Lockout Tagout Training

Introduction

Lockout Tagout training is a non-negotiable when it comes to workplace safety. According to research from the Electrical Safety Foundation International (ESFI), contact with electricity is one of the leading causes of death in the workplace, with an average of 150 fatalities happening every year from 2011 to 2023. This research was compiled using data from the Occupational Safety and Health Administration (OSHA) and the U.S. Bureau of Labor Statistics (BLS).

What is Lockout Tagout?

Lockout/Tagout (LOTO) is a safety measure taken to protect workers from injury caused by the accidental release of hazardous energy during equipment servicing. 

It involves shutting down and isolating energy sources and then applying a physical lock or tag to prevent the machinery from restarting until the work is safely complete.

What is Hazardous Energy: Definition and Types 

Hazardous energy refers to any form of energy that poses a serious risk of injury or death to employees working nearby. Proper Lockout/Tagout (LOTO) procedures are designed to control and contain these types of energy to keep workers safe.

Here are the most common forms of hazardous energy managed through LOTO:

1. Electrical Energy

    

   • Live wires, batteries, power grids capacitors.

      

   • Risk: Electric shock, arc flash, accidental machine startup.
2. Mechanical Energy
   • Moving parts like blades, gears, belts, or compressed springs.

      

   • Risk: Crushing, cutting, or pinching injuries.
3. Hydraulic Energy
   • Pressurized fluid systems (e.g., lifts, cylinders).

      

   • Risk: Sudden movement of machine parts or hydraulic line failure can cause crush injuries or dangerous high-pressure fluid injection injuries.
     
4. Pneumatic Energy
   • Compressed air powering tools or machines.

      

   • Risk: Forceful ejection of parts or tools can send debris or equipment components flying, creating serious impact hazards for anyone nearby.
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5. Thermal Energy
   • Steam, hot surfaces, or heated fluids.

      

   • Risk: Burns or fire hazards during maintenance.
6. Chemical Energy
   • Stored chemicals that could react or release gas/pressure.

      

   • Risk: Explosions, burns, or toxic exposure.
7. Gravitational Energy
   • Suspended parts or machinery that could fall when released.

      

   • Risk: Crushing injuries or impact from falling objects.

Training Employees

As an employer, it is your responsibility to ensure your facility is OSHA-compliant and that your crew has the necessary information and resources to stay safe. According to OSHA’s LOTO Fact Sheet, employees must be trained in at least three key areas:

• The specifics of your company’s energy control program

   

• The LOTO procedures that apply directly to their role
• The OSHA standards that govern lockout/tagout across all worksites
  

Here is a brief checklist as a jumping-off point for ensuring your LOTO training is effective and OSHA-approved. 

1. Energy Control Program Overview

Explain the purpose and scope of your company’s LOTO program. This involves identifying and notifying employees of all hazardous energy sources in your facility, as well as providing theme with a write-up of your LOTO procedures.

2. Role-Specific Training

Identify which employees are authorized, affected, or other. Authorized employees are those who directly perform LOTO procedures, affected employees operate or work near the equipment being serviced, and “other” refers to employees who may be in the area but do not operate or service the equipment.

Here’s a general guideline to help you understand the different levels of training required for each type of employee:

• Train authorized employees on full lockout procedures, device use, and verification.

   

• Train affected employees on what a lockout means and when not to restart equipment.
• Ensure other employees understand LOTO warnings and signage.

3. Lockout Devices & Tools

Training must include a review of OSHA’s 29 CFR 1910.147 Lockout/Tagout standard with a focus on how it applies to your facility and workforce. Employees should understand the potential consequences of noncompliance, including steep fines and serious injuries. Employers are also responsible for documenting completed training for each employee to maintain compliance and ensure accountability.

4. OSHA Standards & Compliance

• Review key requirements from OSHA standard 29 CFR 1910.147

   

• Reinforce that violating LOTO procedures can result in fines or serious injury
• Document each employee’s training completion

5. Refresher Training

LOTO training is not a one-and-done process. It should be ongoing and evolve alongside industry standards and workplace changes. This means conducting annual refresher training, updating procedures when new equipment is introduced, and tracking any violations or near-misses to ensure corrective training.

It’s also important to use real equipment during training sessions whenever possible, so employees can see and practice proper handling techniques in a realistic setting.

Consequences of Ignoring LOTO Procedures

Failure to abide by OSHA’s Lockout/Tagout procedures can result in devastating physical injuries. Workers who are exposed to uncontrolled energy face serious risks, including crush injuries, burns, electrical shock, amputations, and even death. These accidents are sudden, violent, and entirely preventable with the right safeguards in place.

From an employer standpoint, noncompliance can also come with steep OSHA penalties:

• Up to $16,131 per serious or other-than-serious violation

   

• Up to $161,323 per willful or repeat violation
• $16,131 per day for failure to abate past deadlines

These fines don’t include the added costs of downtime, legal claims, higher insurance premiums, or permanent harm to your company’s reputation!

Protect Your People. Protect Your Business.

Lockout/Tagout training is more than just a regulatory requirement. It’s a critical investment in your team’s safety and your operation’s success. From preventing lethal injuries to avoiding costly OSHA violations, proper LOTO procedures create a safer, more compliant workplace.

Maybury Material Handling offers hands-on, OSHA-certified safety training designed to help your crew stay informed, prepared, and protected. Whether you’re just getting started or need a refresher course, we’ll work with you to build a program that fits your team and your equipment.

Ready to schedule your LOTO training session? Contact Maybury today to learn more or book on-site training with our safety experts.