Introduction
Lockout/Tagout (LOTO) procedures are essential for keeping workers safe during equipment service and maintenance. They are designed to prevent machines from unexpectedly powering on or releasing stored energy, which can easily result in serious injury or death. While many facilities have a LOTO program in place, common mistakes during the tagout process with locks still put people at risk.
Whether you're a safety manager, facility supervisor, or front-line technician, here are 10 frequent tagout mistakes you’ll want to eliminate, along with how to fix them.
1. Unclear or Incomplete Tags
Tags are your communication link during a lockout. If they’re missing key details like the worker’s name, the date, or the reason for the lockout, you're setting the stage for confusion or unauthorized removal.
Use weather-resistant, clearly printed tags, and make sure every field is filled out. Rhino’s tags by the roll offer a consistent, easy-to-deploy tagging solution that keeps your messaging clear and compliant.
2. Sharing Padlocks Among Workers
Each person working on a lockout must use their own individual padlock. Sharing a lock or using a system with duplicate keys removes personal accountability and creates serious risk. No one should be able to remove a lock except the person who applied it.
Equip your team with keyed-different padlocks like Rhino’s KDL816RD. These are purpose-built for LOTO compliance and feature durable construction, high-visibility red casings, and one key per lock.
3. Failing to Verify Energy Isolation
Locking out the equipment is not enough unless you verify that the energy is fully isolated. Skipping the "try-out" step and assuming the system is safe can result in serious injury.
Always test the equipment after lockout. Press the start button, use a multimeter, or follow the appropriate method for your system to confirm zero energy. Never proceed until you’ve confirmed it is safe.
4. Ignoring Secondary Energy Sources
Many machines use more than one type of energy: electrical, pneumatic, hydraulic, or even stored mechanical energy. Locking the main switch alone may not make the equipment safe.
You need to identify and isolate all energy sources. Review diagrams or equipment manuals, and follow your full lockout procedure to avoid leaving any source uncontrolled.
5. Using a Tag Without a Lock
Tags are meant to supplement locks, not replace them. A tag provides information, but it does not prevent someone from turning on equipment. If a device can be locked, OSHA requires that it must be locked.
Tagout-only procedures are allowed only when a device cannot physically accept a lock. If there’s a way to apply a lock, it should always be used.
6. Improper or Makeshift Locking Devices
Not every lock is suitable for LOTO. Hardware-store padlocks, combination locks, or anything with a shared key system should not be used. Makeshift solutions like zip ties or tape are not reliable and fail to meet compliance requirements.
Use locks made specifically for safety applications. Rhino’s KDL816RD padlocks include critical features such as key retention, durable casing, and keyed-different setups for personal control and accountability.
7. Poor Communication in Multi-Person Lockouts
When more than one person or team is working on the same equipment, communication becomes essential. Without clear coordination, someone might remove a lock too early or not realize others are still at risk.
Use multi-lock hasps or group lock boxes so every worker can apply their own lock. Keep a written log or use shift-change briefings to make sure everyone is aware of who is working on what and when it's safe to remove locks.
8. Inadequate Training or Outdated Procedures
LOTO procedures are only as strong as the training behind them. A common mistake is assuming workers know the right steps without having been properly trained or refreshed.
Each authorized employee must be trained on the specific steps for your facility's lockout/tagout procedures. This includes shutdown, isolation, locking, tagging, verification, and safe re-energization. Regular refreshers should be mandatory, especially after any incident or policy change.
9. Improper Lock or Tag Removal
Locks and tags should only be removed by the person who applied them. If that worker is unavailable, a written and verified removal procedure must be followed. Skipping this step exposes others to serious risk.
You should also avoid the opposite mistake — forgetting to remove locks or tags after the work is done. That can lead to confusion, unnecessary downtime, or someone overriding the system.
10. Leaving Locks or Tags on After Work Is Complete
When the job is finished and the area is safe, all locks and tags should be removed promptly. Leaving them in place creates confusion, slows operations, and can undermine confidence in your LOTO system.
Wrap up the process the same way you started — carefully, deliberately, and with clear communication. Final equipment checks should always include verifying that all lockout devices have been removed and that it’s safe to return the equipment to service.
Conclusion
Mistakes during lockout/tagout aren’t just technical issues — they’re safety failures that put lives at risk. Every one of the errors listed here is preventable with solid training, disciplined procedures, and the right tools.
Evaluate your current LOTO program. Are your workers trained on proper tagging procedures? Do you have the right locks for every job? Are communication and verification steps followed without exception?
If any of those answers are unclear, it’s time to make changes. Start by upgrading your equipment with proven tools like Rhino’s tags by the roll and KDL816RD safety padlocks. Reliable gear and disciplined execution are the foundation of a lockout/tagout program that protects your team — every shift, every time.