In any industrial or maintenance environment, workplace safety is a top priority—especially when dealing with hazardous energy. That’s where the LOTOTO procedure comes into play.
This guide will explain the meaning of LOTOTO, its importance in protecting workers, and how to implement it correctly. Whether you're new to the concept or looking to reinforce your safety program, this article will help you understand what LOTOTO is, how it works, and why it matters.
What Does LOTOTO Stand For?
The LOTOTO meaning is an acronym that stands for:
- LO – Lock Out
- TO – Tag Out
- TO – Try Out
Together, the LOTOTO procedure is designed to ensure that machines or equipment are properly shut off and cannot be accidentally restarted before the completion of maintenance or servicing work.
What is LOTOTO?
LOTOTO is a comprehensive safety process used to control hazardous energy. It protects employees from the unexpected energization or startup of machines during maintenance, repair, or servicing.
LOTOTO Safety Is Essential When:
- Performing electrical or mechanical maintenance
- Servicing equipment with moving parts
- Working around pressurized systems, chemicals, or high heat
- Cleaning or unjamming machinery
By following the LOTOTO procedure, companies drastically reduce the risk of injury or fatality due to unexpected energy release.
Step-by-Step LOTOTO Procedure
To ensure full protection, the LOTOTO procedure involves the following seven key steps:
1. Preparation
- Identify all energy sources involved (electrical, hydraulic, pneumatic, etc.)
- Review machine-specific energy control procedures
- Notify affected employees about the upcoming shutdown
2. Shutdown
- Turn off the equipment using standard shutdown procedures
- Allow moving parts to come to a full stop
3. Isolation
- Physically disconnect or isolate all energy sources (e.g., flip breakers, close valves)
4. Apply the LOTOTO Lock and Tag
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Place a personal lock (LO) on each isolation point
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Attach a LOTOTO tag (TO) to communicate:
- Who is performing the work
- The reason for the lockout
- The date and time of lockout
Each worker must use their own lock and LOTOTO tag for traceability and accountability.
5. Release Stored Energy
- Discharge any residual energy (e.g., bleed air lines, drain capacitors, release spring tension)
6. Try Out
- Attempt to start the machine to ensure it cannot be operated
- Verify that all energy sources are effectively isolated
Try Out is a critical step that validates the lockout and guarantees safety.
7. Perform Maintenance
- Conduct the repair, cleaning, or inspection as needed
Restoring the Equipment
Once the job is done, follow these steps to bring the equipment back online safely:
- Check the area – Ensure all tools are removed, guards are in place, and the work is complete
- Notify team members – Let everyone know the equipment is about to be re-energized
- Remove LOTOTO locks and tags – Only the person who applied the lock and tag can remove them
- Restore power – Reconnect energy sources and restart equipment following standard procedures
Why LOTOTO Safety Matters
Failure to follow proper LOTOTO safety procedures can result in severe injuries, amputations, or fatalities. The procedure isn’t optional—it’s a critical part of any robust safety program and often mandated by regulatory bodies like OSHA.
Companies that implement effective LOTOTO training help ensure that all employees:
- Understand what is LOTOTO
- Know how to recognize and control hazardous energy
- Are trained to follow correct lockout/tagout procedures
- Use the correct LOTOTO tag and equipment
LOTOTO Training: A Must-Have for Workplace Safety
To implement an effective LOTOTO program, you must provide comprehensive LOTOTO training for all authorized and affected employees. Training should cover:
- The meaning of LOTOTO
- When and how to apply locks and tags
- How to safely isolate and verify equipment
- The importance of never bypassing safety procedures
Regular refresher courses and audits help maintain compliance and improve safety performance.
Final Thoughts
Understanding what is LOTOTO—and applying it correctly—can mean the difference between a safe workday and a serious incident. By following the LOTOTO procedure and investing in proper LOTOTO training, companies protect their most valuable asset: their people.
