How Lockout, Tagout, Tryout Helps Improve Health & Safety in the Workplace
Posted on: 13/01/2025
Author: Mark Smith: Business Development Manager, Spectrum Industrial
Thousands of workplace accidents occur every year due to improper control of hazardous energy during equipment maintenance and servicing. Lockout, tagout, tryout (LOTOTO) programmes will help prevent accidents and improve health and safety in the workplace, but they must be implemented and followed correctly.
As the Business Development Manager at Spectrum Industrial, I visit and survey sites across many industries and have seen it all! Unfortunately, LOTOTO is not always at the forefront of the Health & Safety agenda for various reasons. This can lead to high levels of risk for workers and has the potential to have devastating consequences.
Over and above the risks to workers, businesses can also be fined for not ensuring a safe system of work is in place to ensure that machinery is effectively isolated and locked out. For example, this bakery in Northamptonshire was fined more than £360,000 in 2024 after an employee lost a finger in machinery.
Lockout Tagout Tryout Explained
In a nutshell, lockout, tagout, tryout is the process of controlling hazardous energy sources to protect workers during equipment maintenance or servicing.
By controlling hazardous energy, LOTOTO protects workers from risks such as electrocution, crushing injuries, burns, and more.
Our free ‘Total Isolation Guide & Handbook’ provides detailed steps and procedures to follow for achieving a successful isolation. View the handbook here.
Critical Elements of an Effective LOTOTO Programme
Please don’t forget you may need to adapt your approach and intervene as and when new colleagues start!
With that in mind, I strongly recommend implementing machine-specific energy control procedures. These procedures are a fantastic way to ensure colleagues have the necessary information to lockout effectively. Ask yourself: is it worth the risk?
Machine-specific energy control procedures should:
3. The Right Equipment – Without the proper tools, even the best procedures fall short
Providing operators with the right tools to successfully do their job is essential for keeping colleagues safe.
Understanding the various types of isolation points across your site allows you to identify the specific lockout equipment required for each area. Additionally, it’s important to consider the quantities of lockout items and how and where they are stored across the site.
For example, some of the most effective LOTOTO controls I have seen feature small custom lockout shadow boards next to each machine with the correct equipment to isolate and lockout that specific machine.
Some key considerations are:
Spectrum Industrial stocks a range of LOTOTO equipment and specialises in the production of custom shadow boards.
Tips for Health & Safety Managers
As experts in LOTOTO, we see many situations and problems each day. With over 30 years of experience helping businesses manage and reduce safety risks, we have compiled three top safety tips for health and safety managers.
Encourage a safety-first mindset by:
Spectrum Industrial: Your Partner in Safety
At Spectrum Industrial, we understand that effective LOTOTO programs require more than just knowledge. They need the right tools and support. Based in Doncaster, UK, we provide a comprehensive range of lockout, tagout, and safety signage solutions tailored to your needs. Whether you’re starting from scratch or looking to enhance your existing procedures, our team of experts is here to help.
By implementing robust lockout, tagout, tryout procedures, you’re not just complying with regulations, you’re protecting lives and creating a culture of health and safety.
If you need support with lockout, tagout, tryout to improve health and safety in your workplace, contact Spectrum Industrial today.
Thousands of workplace accidents occur every year due to improper control of hazardous energy during equipment maintenance and servicing. Lockout, tagout, tryout (LOTOTO) programmes will help prevent accidents and improve health and safety in the workplace, but they must be implemented and followed correctly.
As the Business Development Manager at Spectrum Industrial, I visit and survey sites across many industries and have seen it all! Unfortunately, LOTOTO is not always at the forefront of the Health & Safety agenda for various reasons. This can lead to high levels of risk for workers and has the potential to have devastating consequences.
Over and above the risks to workers, businesses can also be fined for not ensuring a safe system of work is in place to ensure that machinery is effectively isolated and locked out. For example, this bakery in Northamptonshire was fined more than £360,000 in 2024 after an employee lost a finger in machinery.
Lockout Tagout Tryout Explained
In a nutshell, lockout, tagout, tryout is the process of controlling hazardous energy sources to protect workers during equipment maintenance or servicing.
- Lockout: Shut down machinery and isolate energy sources
- Tagout: Apply physical locks and tags to warn others and identify the responsible engineer
- Tryout: Verify the system is fully de-energised before work begins. ‘Tryout’ is often overlooked but is critical for preventing accidents
By controlling hazardous energy, LOTOTO protects workers from risks such as electrocution, crushing injuries, burns, and more.
Our free ‘Total Isolation Guide & Handbook’ provides detailed steps and procedures to follow for achieving a successful isolation. View the handbook here.
Critical Elements of an Effective LOTOTO Programme
- Comprehensive Training
- Proper use of LOTOTO equipment e.g. padlock, hasps, tags etc
- Identification of energy sources e.g. Electrical, mechanical, hydraulic, steam etc
- Your business-specific LOTOTO process – Spectrum Industrial’s best practice process detailed in our ‘Total Isolation Guide & Handbook’
Please don’t forget you may need to adapt your approach and intervene as and when new colleagues start!
- Robust Energy Control Procedures
With that in mind, I strongly recommend implementing machine-specific energy control procedures. These procedures are a fantastic way to ensure colleagues have the necessary information to lockout effectively. Ask yourself: is it worth the risk?
Machine-specific energy control procedures should:
- Identify all energy sources for each piece of equipment
- Provide step-by-step instructions for isolating and securing energy sources
- Detail LOTOTO equipment needed
- Location of and image of isolation point to provide absolute clarity
- Reminder of the ‘tryout’ step to verify isolation
3. The Right Equipment – Without the proper tools, even the best procedures fall short
Providing operators with the right tools to successfully do their job is essential for keeping colleagues safe.
Understanding the various types of isolation points across your site allows you to identify the specific lockout equipment required for each area. Additionally, it’s important to consider the quantities of lockout items and how and where they are stored across the site.
For example, some of the most effective LOTOTO controls I have seen feature small custom lockout shadow boards next to each machine with the correct equipment to isolate and lockout that specific machine.
Some key considerations are:
- Padlocks – Many sites generally utilise red padlocks. However, implementing a colour-coded system can be very effective e.g. Operators = RED / Engineers = BLUE / Long Term Isolations = BLACK / Contractors = YELLOW
- Custom Lockout Shadow Boards – Custom lockout shadow boards provide a clear and organised way to display lockout equipment, enabling a swift reaction when required. These boards are particularly popular with sites interested in implementing the Lean 6 methodology: Set In Order – Orderliness – Arranging and labelling only necessary items for easy use and return by anyone
Spectrum Industrial stocks a range of LOTOTO equipment and specialises in the production of custom shadow boards.
Tips for Health & Safety Managers
As experts in LOTOTO, we see many situations and problems each day. With over 30 years of experience helping businesses manage and reduce safety risks, we have compiled three top safety tips for health and safety managers.
- Conduct a Comprehensive Risk Assessment
- Create a Health & Safety Culture
Encourage a safety-first mindset by:
- Recognising and rewarding employees who consistently follow procedures
- Addressing non-compliance promptly and constructively
- Involving employees in the creation and review of LOTOTO procedures
- Regularly Review and Update Your Programme
Spectrum Industrial: Your Partner in Safety
At Spectrum Industrial, we understand that effective LOTOTO programs require more than just knowledge. They need the right tools and support. Based in Doncaster, UK, we provide a comprehensive range of lockout, tagout, and safety signage solutions tailored to your needs. Whether you’re starting from scratch or looking to enhance your existing procedures, our team of experts is here to help.
- Lockout Tagout Site Surveys: Our surveys will review your LOTOTO process for when machinery is undergoing repair or maintenance and advise on the process and products required to ensure machinery is safely isolated during repair or routine maintenance
- Lockout Tagout Training: Our team offers training programmes for our resellers and their sales teams, as well as mobile training events for staff to get hands-on with our products
By implementing robust lockout, tagout, tryout procedures, you’re not just complying with regulations, you’re protecting lives and creating a culture of health and safety.
If you need support with lockout, tagout, tryout to improve health and safety in your workplace, contact Spectrum Industrial today.
