Lockout/Tagout (LOTO) Training: Control the Energy, Save a Life
On any jobsite, the smallest mistake can change everything. A valve left open. A breaker not tagged. Someone assuming the system is off when it’s still live. These split-second oversights are what Lockout/Tagout (LOTO) training was built to prevent and why it remains one of the most cited OSHA standards in the U.S. year after year.
When a worker takes the time to apply a lock and verify isolation, they’re not slowing down production, they’re protecting lives.
6-7 minute read
On any jobsite, the smallest mistake can change everything. A valve left open. A breaker not tagged. Someone assuming the system is off when it’s still live. These split-second oversights are what Lockout/Tagout (LOTO) training was built to prevent and why it remains one of the most cited OSHA standards in the U.S. year after year.
When a worker takes the time to apply a lock and verify isolation, they’re not slowing down production, they’re protecting lives.
The Hidden Risk of Stored Energy
Electricity, hydraulics, pneumatics, mechanical tension, energy doesn’t vanish when you hit the “off” switch. It hides inside equipment, waiting for a trigger. That’s why OSHA’s Control of Hazardous Energy (29 CFR 1910.147) standard is so specific: before anyone performs maintenance or servicing, the machine must be fully isolated from all energy sources.
Failure to follow these steps has real consequences. According to OSHA, compliance with the LOTO standard prevents an estimated 120 deaths and over 50,000 injuries each year. Those aren’t abstract numbers, they’re real workers who went home because their teams did things right.
Every worker who repairs, cleans, or adjusts powered equipment — from electricians and millwrights to mechanics and machine operators, must understand how to identify energy sources, isolate them, and confirm they stay locked out.
When “Routine” Work Becomes Dangerous
A common phrase heard on job sites: “We’ve done this a thousand times.” That’s often when it happens. The task seems simple, swap a belt, clear a jam, inspect a valve, but without proper lockout/tagout, even small maintenance jobs can trigger catastrophic releases of energy.
One worker might think the system is down while another restarts it remotely. Hydraulic pressure can release unexpectedly. Stored mechanical energy can cause moving parts to spin or snap. Each scenario is preventable with one consistent process: LOTO.
What Proper LOTO Looks Like
Lockout/Tagout isn’t a single step, it’s a system.
A complete program includes:
Identifying all hazardous energy sources (not just electrical)
Isolating the equipment from energy
Locking and tagging all isolation points
Releasing stored energy safely
Verifying zero energy before work begins
Communicating with everyone involved
Skipping any step introduces risk. That’s why companies that invest in consistent, standardized LOTO training see fewer incidents, fewer citations, and stronger safety cultures.
At Kelly Safety, we designed our Lockout/Tagout (LOTO) Online Course to make these procedures second nature. It’s OSHA-compliant, easy to complete online, and created specifically for the demands of industrial and construction environments — not just classroom theory.
Inside the LOTO Online Course
This course takes workers through real-world examples, visuals, and scenarios that demonstrate:
The purpose and scope of OSHA’s LOTO standard
Different types of hazardous energy (electrical, thermal, hydraulic, etc.)
How to create and use machine-specific LOTO procedures
The difference between authorized, affected, and other employees
Steps for verifying isolation and restoring equipment safely
Best practices for inspections, training documentation, and re-certification
The course can be completed at your own pace and is accessible on desktop, tablet, or phone, making it ideal for contractors and employers managing multiple sites or shifts.
The Cost of Getting It Wrong
OSHA consistently lists Lockout/Tagout among its Top 10 most frequently cited standards, often resulting in fines exceeding $150,000 per violation. But the real cost isn’t financial — it’s human.
When someone skips LOTO, they’re gambling with someone else’s safety.
A single incident can shut down operations, damage equipment, and destroy a company’s reputation overnight. More importantly, it can cost a worker their ability to provide for their family. Training prevents that by giving every employee a clear, consistent process to follow, no guesswork, no assumptions.
Why LOTO Training Builds a Safer Culture
LOTO is more than compliance; it’s a reflection of a company’s culture. When workers know they have the authority and expectation to lock out equipment, it builds confidence and accountability. It also signals to new employees that safety isn’t just a policy, it’s a priority.
Regular refreshers and retraining ensure that LOTO remains effective over time. Workers rotate, machines change, and processes evolve — so continuous education keeps teams aligned with current OSHA standards and best practices.
Kelly Safety’s online LOTO course gives you the flexibility to train workers whenever it fits your schedule, whether it’s onboarding new hires or renewing certifications for experienced technicians.
The Kelly Safety Difference
At Kelly Safety, we believe safety training shouldn’t feel like a checkbox. It should feel like a conversation, clear, practical, and built for people who actually work in the field.
Our instructors and course designers focus on what really matters: helping you protect your crew, stay compliant, and finish every shift safely.
We’re not a faceless platform, when a worker calls us, we answer. That’s what sets Kelly Safety apart.
Get Certified and Take Control of the Energy
Lockout/Tagout saves lives, plain and simple. The right training gives your crew the confidence to take control, communicate clearly, and protect each other from unseen risks.
Don’t wait for an incident or inspection to realize the importance of proper LOTO.
Start today and make safety part of your daily routine.
👉 Enroll in the Lockout/Tagout (LOTO) Online Course to get certified, stay compliant, and lead by example.