Effective Lockout/Tagout Is a Crucial Component for Preventing Workplace Injuries

By Tyler Doupe'

Working with heavy machinery carries a certain amount of intrinsic risk even under the most ideal circumstances, but adhering to safety best practices goes a long way. Observing proper lockout/tagout (LOTO) procedures leads to a dramatic reduction in on-the-job injury and death. When lockout/tagout standards aren’t properly observed, the probability of an unforeseen tragedy multiplies exponentially.

A Real-Life Tragedy

A sobering reminder of the inherent risk associated with working around heavy machinery transpired not long ago. In March of 2026, Gregory K., a 61-year-old employee at a Ford Motor Company transmission plant in Sharonville, Ohio, was fatally wounded by a press machine.

The machine was undergoing routine maintenance when it unexpectedly came online and pinned Gregory. First responders are referring to the incident as an industrial accident at this time. Gregory’s untimely passing is currently under investigation by OSHA, the Hamilton County Coroner’s Office, and administrative staff at Ford Motor Company.

To ensure employees stay as safe as possible when performing maintenance on heavy machinery, they must be adequately trained by their employer in safety best practices, including lockout/tagout.

The Mechanics of LOTO

The lockout portion of lockout/tagout involves disabling the energy source that powers the machine. This requires physically locking the source of hazardous energy that provides power to the equipment undergoing maintenance. The person conducting the repairs holds on to the key for safekeeping to ensure the machine isn’t inadvertently powered back on.

The tagout component involves tagging the lock with information regarding who locked the machine down, why they locked it, and when they did so. This serves as a signal that the machine is undergoing maintenance and clearly conveys that it should remain out of service until further notice.

Effective Use of LOTO

Effective lockout/tagout involves more steps than just killing the power to a machine. Equipment isn’t in full LOTO mode until all of the following conditions have been met:

• The machine-specific written energy control procedure has been reviewed
• All affected employees have been notified 
• All energy sources have been successfully identified
• The machine has been shut down properly
• All energy sources have been isolated
• Locks have been applied to each energy-isolating device
• Tags have been attached to all locking mechanisms
• Stored energy has been successfully discharged
• Isolation has been verified
• And all controls are set to the ‘neutral’ or ‘off’ position

With all of the aforementioned checks and balances in place, workers can more effectively mitigate the risk associated with servicing and maintaining industrial equipment.

If you need an in-depth rundown on lockout/tagout procedures, OSHAcademy Course 710: Energy Control Program (Lockout/Tagout) covers the subject in greater detail.