Lockout/tagout refers to procedures that protect employees from sudden and accidental start-ups of the machine; re-energizing the equipment can be dangerous for people close to the machine, especially if the worker believes that the equipment has been safely shut down. Before maintenance and repair work begins, it must be ensured that the dangerous machine is completely shut down and cannot be accidentally started.

       Lockout/tagout is especially suitable for any workplace with industrial equipment (such as motors) and should always be used in conjunction with other safety regulations. The lockout/tagout process should be completed after wearing the correct personal protective equipment (PPE) and following the eight stages of the procedure.

       For personal safety, the Occupational Safety and Health Administration (OSHA) requires a formal lockout/tagout plan to ensure that employees work in a safe environment. Every time the machine needs maintenance or cleaning, an effective lockout/tagout procedure should be carried out; this routine has been developed into a lockout/tagout trial (LOTOTO), the focus is to try to restart the device. This trial phase ensures the success of the lockout/tagout procedure. It uses eight steps to achieve:

       Make sure you have determined the correct procedure for shutting down and restarting a particular device/machine. Prepare to shut down the equipment and highlight any potential hazards that may occur. Notify all employees that the lockout procedure is being performed and how long it will affect them.

       Explain in detail and write down shutdown instructions to reduce the risk of damage to the equipment and ensure everyone's safety. Ensure that the shutdown instructions are in the correct order and are clearly written to other workers; following the manufacturer's shutdown instructions will ensure that the equipment shuts down safely.

       Ensure that equipment isolation points are identified, marked, and disconnected from all primary and secondary power sources. Ensure that all energy sources are isolated, including water, steam, electricity, and natural gas. If needed, determine the process that will release any remaining pressure or energy in the machine.

       Apply locking devices to all energy isolation points and ensure that they are marked according to your company's safe working procedures. Use appropriate locking devices and tagging devices.

       Check the system thoroughly to ensure that all moving parts have stopped, and take measures to prevent residual energy. Releasing the tension in the spring, supporting parts that may fall, and preventing moving parts in the hydraulic system are all examples of how to control stored energy at this stage.

       After disconnecting the primary and secondary energy sources, try to start the device to verify that the lock is successful. Check the system to make sure it will not restart, then return all switches to the off position.

       At this stage, you can safely complete the maintenance or cleaning work required for the equipment/machinery. Be vigilant for any potential hazards or equipment areas that may be restarted.

       After the work is completed, the final stage of lockout/tagout can be carried out, that is, the device can be restarted. Only the person responsible for the application lock can remove it. Once the last locking device is removed, the device can be re-powered and restarted according to the manufacturer's instructions.

       Facts have proved that the LOTOTO procedure is one of the most effective procedures to ensure worker safety and a thorough method to safely isolate equipment. By implementing this procedure, the possibility of accidental injury or even death during equipment maintenance or repair work is greatly reduced.

       In order to complete the LOTOTO procedure, all workers should receive thorough training on the methods and use of appropriate equipment. This is essential to ensure a safe lock.