Free written program · 29 CFR 1910.147
Lockout/Tagout Program Template: Build Your Energy Controls
A lockout/tagout program organizes the steps people follow to isolate hazardous energy before machine servicing. The template addresses employee roles, shutdown, isolation, stored energy, verification, return to service, inspections, and training. Maintenance supervisors and equipment owners can use it as the program framework, but must add machine-specific instructions that identify every energy source and the means of controlling it.
The full lockout/tagout program template
Lockout/Tagout (LOTO) Program. Blanks in [brackets] are for your own details.
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Energy control procedures for servicing and maintenance of machines and equipment to prevent unexpected startup.
1. Purpose & Scope
This program establishes procedures to control hazardous energy during servicing and maintenance of machines and equipment at [Company Name]. It applies to all energy sources including electrical, mechanical, hydraulic, pneumatic, chemical, thermal, and gravitational energy. All employees involved in servicing, maintenance, or operating equipment are covered by this program.
2. Authorized & Affected Employees
Authorized Employees: Trained individuals who perform LOTO on machines. They must use their own assigned lock and key. Affected Employees: Workers whose operations are affected by LOTO. They must understand LOTO but do not apply locks. Other Employees: All other workers who must recognize LOTO and not attempt to restart locked-out equipment. A current list of authorized employees is maintained by [Name/Department].
3. Lockout/Tagout Procedure
Step 1: NOTIFY all affected employees. Step 2: SHUT DOWN equipment using normal stopping procedure. Step 3: ISOLATE all energy sources (disconnect switches, valves, etc.). Step 4: APPLY lockout/tagout device — each authorized employee applies their OWN lock. Step 5: RELEASE stored energy (bleed hydraulic/pneumatic lines, block suspended parts, discharge capacitors). Step 6: VERIFY zero energy state — attempt to start equipment to confirm de-energization, then return controls to "off" position.
4. Restoring Equipment to Service
- Inspect work area to ensure all tools and materials are removed.
- Verify all guards and safety devices are reinstalled.
- Ensure all employees are clear of the danger zone.
- Notify affected employees.
- Remove lockout/tagout devices — each employee removes ONLY their own lock.
- Re-energize equipment. If an authorized employee is absent and their lock must be removed, the employer must verify the employee is not at the facility, make reasonable efforts to contact them, and ensure they are informed before their next shift.
5. Periodic Inspection
LOTO procedures must be inspected at least annually. Inspections include:
- Review by an authorized employee NOT involved in the specific procedure being inspected.
- Observation of authorized employees performing LOTO.
- Correction of any deficiencies found.
- Documentation of inspection date, equipment, employees, and inspector. Group LOTO procedures have additional requirements for coordination.
6. Training Requirements
Authorized employees: Trained on energy control procedures, equipment-specific LOTO, and hands-on lock/tag application. Affected employees: Trained to recognize LOTO and prohibited from restarting locked-out equipment. Other employees: Awareness training. Retraining required: when procedures change, when inspections reveal deficiencies, or when new equipment is installed.
The printable copy adds effective and review dates and approval signature lines for management and the safety manager.
A starting point, not legal advice. Have a qualified person check it against your site, your state's rules and the standard before you rely on it.
Lockout/tagout program: when it’s needed
For general industry, 29 CFR 1910.147 applies to servicing and maintenance where unexpected startup, energization, or released stored energy could injure an employee. The energy control program includes documented procedures under 1910.147(c)(4), periodic inspections at least annually under (c)(6), and training under (c)(7). Limited exceptions exist, so evaluate the task rather than assuming every adjustment needs the same method. Construction has different applicable provisions; do not transfer this general industry program to construction work without reviewing the governing rules.
How to use this lockout/tagout program template
- Identify machines requiring energy control and record electrical, hydraulic, pneumatic, gravity, thermal, and other energy sources for each.
- Write equipment-specific procedures showing shutdown controls, isolation points, stored-energy restraints, and verification methods before maintenance starts.
- Name authorized workers and explain how affected operators receive notice before shutdown and before equipment returns to service.
- Add practical arrangements for shift changes, group lockout, contractors, and exceptional lock removal before those situations arise.
- Schedule annual procedure inspections with a separate authorized inspector, document findings, and correct any training or procedure gaps.
Before you use this lockout/tagout program template: what to fill in and check
- Machine identifiers, isolation device locations, and sources that can reaccumulate stored energy.
- Assigned locks, keys, tags, blocking devices, and verification instruments for authorized personnel.
- Shift handoff arrangements and the employer’s documented process for exceptional lock removal.
- Whether the activity is general industry servicing, construction, or electrical work governed by separate provisions.
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Lockout/tagout program questions
Is a stop button enough to lock out a machine?
No. A control button stops normal operation but does not isolate the energy supply. The procedure needs energy-isolating devices, such as appropriate disconnects or valves, plus controls for stored energy. Identify the actual devices on each machine. Verify isolation using methods suited to its hazards before anyone enters the danger zone; a generic instruction to press start cannot address every energy source.
Who can perform the annual lockout/tagout inspection?
Under 29 CFR 1910.147(c)(6), the inspector must be an authorized employee other than the employees using the procedure being inspected. The inspection checks whether the energy control procedure and its requirements are being followed. Certify the inspection with the machine or equipment identified, inspection date, included employees, and inspector. Use observed problems to revise instructions and provide retraining where needed.
Can a supervisor remove someone else’s lock?
Not simply because production needs to resume. Each device is normally removed by the employee who applied it. The exception in 29 CFR 1910.147(e)(3) requires specific employer procedures and training. These include verifying the employee is absent from the facility, making reasonable contact efforts, and making sure the employee knows about removal before returning to work. Document that process before an absence creates pressure.