Lockout/Tagout Permit Manager - LOTO Safety Tool

Create and manage lockout/tagout permits for equipment energy isolation. This tool helps safety managers, maintenance supervisors, and industrial electricians document every step of the LOTO process: identifying energy sources, assigning locks and tags, recording verification steps, and generating printable permits for compliance documentation.

OSHA Standard 29 CFR 1910.147 requires written energy control procedures for any equipment where unexpected startup or release of stored energy could cause injury. Proper LOTO documentation protects your workers, satisfies OSHA inspectors, and creates a defensible record if an incident is ever investigated.

This tool supports multiple energy source types - electrical, pneumatic, hydraulic, thermal, gravitational, and chemical - because most industrial equipment has more than one energy source that must be isolated. The permit system tracks who applied each lock, when it was applied, and whether zero-energy verification was completed.

Pro Tip: Always verify zero energy state after lockout - never trust labels alone. Test, try, test: attempt to restart the equipment after lockout to confirm isolation, then test with appropriate instruments to verify zero energy.

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Start Using This Tool See How It Works

How It Works

Select Equipment

Identify the equipment or machine being serviced. Enter the equipment name, ID number, location, and a brief description of the maintenance work to be performed.
Identify Energy Sources

Document every energy source associated with the equipment: electrical (voltage, phase), pneumatic (PSI), hydraulic (PSI), thermal (temperature), gravitational (elevated components, springs), and chemical (process fluids, gases). Missing an energy source is the most common cause of LOTO-related fatalities.
Assign Locks & Tags

Record the lock number, tag number, and name of the authorized employee applying each lock. Each worker exposed to the hazard must apply their own lock. Group LOTO procedures require a primary authorized employee to coordinate.
Document Verification Steps

Record the zero-energy verification method for each energy source. This may include attempting to start the equipment, checking voltage with a meter, bleeding pressure gauges, and verifying that moving parts are at rest.
Print or Export Permit

Generate a printable LOTO permit that includes all energy sources, lock assignments, and verification steps. Keep the printed permit at the equipment location for the duration of the maintenance work.

Built For

Manufacturing plant maintenance departments creating standardized LOTO procedures
OSHA compliance documentation for annual safety audits and inspections
Contractor coordination when outside workers perform maintenance on your equipment
Equipment repair and maintenance planning with formal energy isolation documentation
Safety training exercises using realistic LOTO permit scenarios
Post-incident investigation records showing LOTO procedures were followed
Multi-craft maintenance jobs requiring coordination between electrical, mechanical, and process teams

Features & Capabilities

Multi-Energy Source Tracking

Track all six categories of hazardous energy on a single permit: electrical, pneumatic, hydraulic, thermal, gravitational, and chemical. Each source gets its own isolation point, method, and verification step because real equipment rarely has just one energy source.

Lock & Tag Assignment

Record individual lock and tag numbers for each authorized employee. Supports both individual LOTO (one worker, one lock per point) and group LOTO (multiple workers under a primary authorized employee with a lock box).

Verification Checklist

Built-in checklist for zero-energy verification steps. Prompts the user to document how each energy source was verified as isolated - not just locked out, but proven to be at zero energy state.

Printable Permits

Generate formatted, printable LOTO permits that can be posted at the equipment location during maintenance. Includes all required information: equipment ID, energy sources, lock assignments, verification records, and authorized personnel.

Equipment Database

Save equipment profiles with their associated energy sources so you do not have to re-enter the same information for repeat maintenance. Standardizes procedures across shifts and ensures no energy sources are forgotten.

Group LOTO Support

Handles group lockout/tagout scenarios where multiple maintenance workers need to apply their individual locks. Tracks the primary authorized employee, the group lock box, and each individual worker's lock application and removal.

Comparison

Energy Source Type	Examples	Common Isolation Method	Verification Method
Electrical	Motors, heaters, control circuits	Disconnect switch, breaker lockout	Voltage tester on load side
Pneumatic	Air cylinders, blow-off nozzles	Valve lockout, bleed valves	Check pressure gauge at zero
Hydraulic	Presses, lifts, cylinders	Valve lockout, bleed/block	Check pressure gauge, lower rams
Thermal	Steam lines, ovens, heated dies	Valve lockout, cool-down period	Temperature measurement
Gravitational	Elevated platforms, springs, counterweights	Blocking, pinning, cribbing	Visual inspection, push test
Chemical	Process lines, tanks, gas feeds	Valve lockout, blank/blind	Atmosphere testing, drain verification

Frequently Asked Questions

OSHA 29 CFR 1910.147 (The Control of Hazardous Energy) requires employers to establish an energy control program with written procedures, employee training, and periodic inspections. The standard applies to the servicing and maintenance of machines and equipment where unexpected energization or release of stored energy could cause injury. Employers must provide locks, tags, and other hardware, train authorized and affected employees, and conduct annual procedure audits.

Three categories of employees require training. Authorized employees (those who perform LOTO) need full training on energy control procedures, lock/tag application, and zero-energy verification. Affected employees (those who operate the equipment) need awareness training so they understand why equipment is locked out and that they must never attempt to restart it. Other employees (those who work in areas where LOTO is used) need basic awareness so they do not disturb locks or tags.

Group LOTO applies when multiple maintenance workers service the same equipment simultaneously. A primary authorized employee coordinates the lockout, applies locks at all energy isolation points, and places keys in a group lock box. Each individual worker then applies their personal lock to the lock box before beginning work. No single person can remove the group locks until every worker has removed their personal lock, ensuring no one is left at risk when the equipment is re-energized.

OSHA requires at least one annual inspection of each energy control procedure. The inspection must be conducted by an authorized employee who is not the one routinely performing the procedure being audited. The audit must verify that employees understand and follow the written procedures. Many facilities exceed this minimum by conducting quarterly audits and incorporating LOTO observations into routine safety walks.

LOTO violations are among OSHA's most frequently cited standards. Penalties for serious violations can exceed $16,000 per instance, and willful or repeat violations can reach $160,000 or more per instance. Beyond fines, LOTO failures cause approximately 120 fatalities and 50,000 injuries per year in the United States. The human cost far exceeds any financial penalty.

Stored energy is the most frequently overlooked category. Springs, counterweights, elevated machine parts (gravitational energy), pressurized hydraulic accumulators, and capacitors in electrical systems all store energy that persists after the primary power is isolated. Thermal energy in heated dies, steam lines, and process equipment is another common oversight. Chemical energy from residual process fluids in piping and tanks rounds out the top three. A thorough energy survey before any maintenance job is the best defense - which is exactly what this tool helps you document.

OSHA requires written energy control procedures for each machine or piece of equipment. However, a single procedure can cover a group of machines if they all have the same types and magnitudes of hazardous energy, the same isolation points, and the same shutdown/startup sequence. In practice, most facilities need individual procedures for complex equipment (presses, conveyors, packaging lines) and can use generic procedures for simple equipment (single-motor machines with one disconnect).

Disclaimer: This tool assists with LOTO documentation and permit management but does not replace proper OSHA-compliant training, site-specific written energy control procedures, or periodic compliance audits. Every facility must maintain its own written LOTO program reviewed by qualified safety personnel. Always follow your facility's specific procedures and applicable local, state, and federal regulations.

Lockout/Tagout Permit Manager - LOTO Safety Tool

How It Works

Select Equipment

Identify Energy Sources

Assign Locks &amp; Tags

Document Verification Steps

Print or Export Permit