Lockout/Tagout (LOTO)
Lockout/Tagout (LOTO) is a safety procedure used to ensure that equipment is properly shut down, isolated from all energy sources, and cannot be restarted until maintenance or repair work is completed. Lockout involves physically locking energy isolation devices (such as circuit breakers or valves) in the off position, while tagout involves attaching a warning tag to the isolation point. LOTO protects workers from the unexpected release of hazardous energy during servicing.
Why it matters
Failure to properly isolate equipment before maintenance is one of the leading causes of serious workplace injuries and fatalities in industrial settings. LOTO procedures are required by WHS regulations and Australian Standards for any work on plant where there is a risk of exposure to hazardous energy. Proper LOTO compliance prevents electrocution, crushing, burns, and other injuries caused by uncontrolled energy release.
How MapTrack helps
MapTrack supports LOTO workflows by enabling digital isolation permits, recording lockout status against the asset, and ensuring maintenance work orders include required isolation steps before work begins.
Frequently asked questions
When is lockout/tagout required?
LOTO is required whenever a worker could be exposed to hazardous energy during maintenance, repair, cleaning, inspection, or adjustment of plant and equipment. This includes electrical, mechanical, hydraulic, pneumatic, thermal, chemical, and gravitational energy sources. The requirement applies to routine servicing activities, not normal production operations where guards and safety devices provide adequate protection.
What is the difference between lockout and tagout?
Lockout uses a physical lock to hold an energy-isolating device in the safe position, making it impossible to re-energise without the key. Tagout uses a prominent warning tag attached to the isolation point to alert others not to operate the equipment. Lockout provides a higher level of protection because it physically prevents re-energisation. Tagout alone is generally only acceptable when lockout is not physically possible.
Related terms
Compliance Management
Compliance management in asset-intensive industries is the systematic process of ensuring that equipment, operations, and personnel meet all applicable regulatory, safety, environmental, and contractual requirements. It encompasses tracking inspection due dates, certifications, licences, safety checks, environmental obligations, and industry-specific standards. Compliance management requires both proactive scheduling and thorough record-keeping.
Pre-Start Inspection
A pre-start inspection is a systematic check performed on plant, equipment, or vehicles before each use or shift to identify defects, damage, or unsafe conditions. It typically follows a standardised checklist covering safety-critical items such as brakes, steering, lights, tyres, guards, fluid levels, and warning devices. Pre-start inspections are a legal requirement under workplace health and safety regulations in most Australian jurisdictions.
Work Order
A work order is a formal document or digital record that authorises and tracks a specific maintenance task. It typically includes the asset identification, description of work required, priority, assigned technician, parts needed, safety requirements, and completion details. Work orders provide a structured workflow from request through approval, execution, and closeout.
Plant and Equipment
Plant and equipment is a broad term encompassing machinery, vehicles, tools, and other physical assets used in industrial, construction, mining, and commercial operations. In Australian workplace health and safety legislation, ‘plant’ is defined to include any machinery, equipment, appliance, container, implement, or tool, and any component or fitting thereof. The term covers everything from hand tools to heavy earthmoving machinery and cranes.
Corrective Maintenance
Corrective maintenance refers to repair or restoration work carried out after a fault, defect, or failure has been identified in an asset. It may be triggered by an operator report, a failed inspection, or an unexpected breakdown. Corrective tasks range from minor adjustments to major overhauls, depending on the severity of the issue.
See how MapTrack handles lockout/tagout (loto)