Lockout/tagout (LOTO) kits are critical tools for workplace safety and regulatory compliance. These kits contain padlocks, tags, and devices used to isolate hazardous energy sources during equipment servicing. Without proper LOTO procedures and tools, employees are at risk of serious injury or even death from the unexpected startup of machinery. OSHA estimates that proper LOTO practices prevent approximately 120 fatalities and 50,000 injuries annually.
Lockout kits serve as standardized, ready-to-use collections of safety equipment that streamline compliance with OSHA's 29 CFR 1910.147 standard. They eliminate guesswork, ensure availability of approved gear, and help create a culture of safety.
Types of Lockout Kits: Boards, Pouches, Boxes, and Cabinets
There is no one-size-fits-all approach to lockout kits. The type of kit you choose should align with how and where it's used. Here’s a breakdown of the four main types:
Lockout Boards
Purpose: Wall-mounted stations designed for centralized access.
Use Case: Ideal for maintenance shops or production areas where LOTO is frequently performed. Employees know exactly where to find their gear.
Components: Typically include padlocks (keyed differently), lockout hasps, tags, and zip ties. Boards may have labeled hooks and clear pockets for organization.
Mounting: Secure to walls in visible, high-traffic areas near machinery or service areas.
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Lockout Pouches
Purpose: Portable kits for individual technicians.
Use Case: Suited for electricians, field techs, or mobile maintenance staff. They keep essential LOTO gear on-hand.
Components: Usually includes 2–4 padlocks, tags with ties, one or two hasps, and device-specific lockouts (e.g., circuit breakers or plug lockouts).
Storage: Carried on belt or stored in toolboxes. Ideal for personal assignment to authorized employees.
Note: Make sure pouches are restocked after use and inspected regularly for missing or damaged items.
Featured Product: STOPOUT® Lockout Pouch Kit: Circuit Breaker Lockout
Lockout Boxes
Purpose: Comprehensive kits housed in a portable hard case.
Use Case: Best for teams handling complex or multi-point lockouts. Allows maintenance personnel to carry a full set of LOTO gear to job sites.
Components: Typically contain 6+ padlocks, multiple hasps, 25–50 tags, breaker lockouts, plug lockouts, and group lockout provisions.
Storage: Kept in maintenance rooms, tool cribs, or service trucks. Must be returned after use and kept fully stocked.
Featured Product: STOPOUT® Lockout Kit: Standard Lockout Kit
Lockout Cabinets
Purpose: High-capacity storage for LOTO equipment.
Use Case: Centralized supply for entire departments or facilities. Great for managing large quantities of padlocks and tags.
Components: Can be purchased stocked or empty. Stocked cabinets usually include dozens of padlocks, hasps, tags, key organizers, and sometimes device lockouts.
Mounting: Wall-mounted in secure, dry locations like safety offices or maintenance areas.
Inspection: Maintain an inventory checklist, restock regularly, and track issued locks.
Featured Product: Lockout Cabinet - 37 Components Stocked
Best Practices: Storage, Inspection, and Use
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Mounting: Boards and cabinets should be bolted to walls in accessible, high-visibility locations.
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Storage: Assign consistent "home" locations for pouches and boxes to avoid loss.
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Inspection: Regularly inspect kits using a checklist. Check padlocks for function, tags for legibility, and devices for wear.
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Restocking: Refill used tags or replace any damaged items immediately. Use shadow boards or inventory sheets to spot missing components.
Why Kit Type Matters
The right kit type ensures that LOTO is easy, fast, and always compliant. Boards promote visibility and consistency. Pouches offer personal accountability. Boxes bring versatility to complex jobs. Cabinets provide scalable storage for growing teams. Choosing the right solution—or a mix—makes your safety program stronger and more efficient.
A Quick Note on Specialty Kits
Specialty kits exist for specific applications like valve isolation, electrical lockouts, or confined space entry. These are designed for niche scenarios and will be covered in our next blog.
Lockout kits are more than just tools—they’re the front line of protection for your team. Explore our full collection of Lockout Tagout Kits to find the right fit for your facility.