A Lockout/Tagout Failure Can Energize a Machine in an Instant

Lockout uses a physical lock to hold an energy-isolating device in the safe position, while tagout uses a warning tag alone. OSHA prefers lockout because a tag is only a warning; tagout is permitted only when a device cannot accept a lock and equivalent protection is provided.

No. Pressing stop or turning a control switch only pauses operation; the machine can be restarted. Lockout requires isolating each energy source at its disconnect, applying a physical lock, tagging it, and verifying zero energy before servicing.

Only authorized employees trained on the specific equipment and its energy-control procedure may apply locks and tags. Affected and other employees must be trained to recognize lockout and never remove or bypass someone else's lock.

Use group lockout: each authorized worker applies their own personal lock to a group lockout box or hasp. The machine cannot be re-energized until every worker removes their individual lock, so no one is left unprotected.

A serious violation of 29 CFR 1910.147 can exceed $16,000, and willful or repeat violations can surpass $165,000 per instance. Incidents involving amputations or fatalities can also trigger criminal referral and significant civil litigation.

OSHA requires a periodic inspection of energy-control procedures at least annually, performed by an authorized employee not using the procedure being reviewed, to verify workers follow it correctly and to correct any deviations.

After applying locks, the authorized worker verifies isolation by attempting to start the equipment and confirming it will not operate, then returns controls to off. This step confirms all energy sources are truly isolated before servicing begins.

OSHA Scan flags lockout/tagout gaps. It checks whether isolating devices are locked and tagged, whether group locks are applied, and returns the location and the OSHA citation it may relate to.