Solutions for Hazardous Energy Control

What is Lockout/Tagout?

Lockout / Tagout is a planned safety procedure which involves turning off the energy supply of industrial machinery and equipment whilst maintenance work or repairs are being carried out. This procedure protects workers from the risks posed by live machinery or electricity.


Why implement a Lockout/Tagout programme? 

  • Reduced accident rates and injury costs
    EU Figures show that 10 to 15% of all fatal accidents at work and 15 to 20% of all accidents are connected with maintenance. Common injuries include fractures, lacerations, amputations, burns and shocks. Due to the serious nature of many LO/TO accidents, injury-related costs can be exorbitant.


  • Less downtime, higher productivity
    A well-organised LO/TO programme that includes clearly labelled energy sources, easy-to-follow procedures, and readily accessible lockout tools can greatly speed up maintenance and servicing activities. Workers can avoid time-consuming tasks such as tracing pipelines and electrical circuits in order to verify the appropriate energy control points. As a result, maintenance work is completed more efficiently, downtime is reduced and machinery is kept running at peak
    performance levels.


  • Reduced indirect costs
    Accidents can have a significant impact on work scheduling and productivity at the affected job site. The unexpected start-up of equipment can also cause extensive damage to the machinery itself, adding the expense of equipment repairs and replacement to the total cost involved.


How to implement a Lockout/Tagout programme?

Efficient Lockout Programme in 4 Steps

Step [1]


Step [2]


Step [3]


Step [4]

   Audit, policy and procedures


Identification and marking of all energy control points


Proper lockout tools and warning devices


Training and Awareness of New Safety Standard



Step (1) Create energy control (LO/TO) policy & procedures

The first step is to develop and document a lockout policy that identities in detail the purpose and scope of the lockout programme. 
We can help you to create a roadmap for the successful LO/TO programme implementation, where you need to execute an audit of all existing potential sources of hazardous energy, create a list, describe procedures and define responsibilities. 


Why do you need lockout procedures?

- Procedures serve as a check sheet to help employees avoid mistakes and reduce the risk of accidents and injuries. 

- Procedures speed lockout activity, which in turn reduces downtime and improves operational productivity. 

- Documented machine-specific energy control procedures are required by OSHA. 


Step (2) Identify all energy control points

In this step you need to localise and clearly mark all energy control points, including valves, switches, breakers and plugs, with permanently placed labels or tags. Our label makers and Do-It-Yourself Signmarking printing systems together with durable label materials are designed to provide you with reliable and long-lasting identification. 


Step (3) Equip authorised employees with the proper lockout tools and warning devices

Products ranges from LO/TO devices and tools - Padlocks include safety, non-conductive, brass, Lockouts include Valve, Universal and Circuit breakers, Tags, Labels, Lockout Boxes, Padlock Stations and much more!


Step (4) Train employees and promote awareness of safe work practices

There are three level of awareness should be recognised by three group of people within the facilities. 

a) Authorised employee: A person who locks out or tags out machines or equipment in order to perform servicing or maintenance and identifies that equipment have a source(s) of energy that can cause inquiry to the employees. 

- Requires the most in-depth training about LO/TO. 


b) Affected employee: An employee whose job requires him/her to operate or use a machine or equipment on which serving or maintenance is being performed under LO/TO, or whose job requires him/her to work in the area. 

- Needs to be informed about LO/TO and does not attempt to remove lockout devices. 


c) Other employee: Who may encounter lockout being implemented. 

- Need to know the significance of lockout, and to keep away. 



"A co-worker dies, and 160 others have a work-related accident, every 15seconds." - International Labour Organization, 2015. 

Workplaces claim more than 2.3 million deaths per year, including 350,000 fatal accidents and close to 2 million life ending work-related diseases. 

In addition, 313 million accidents happen on the job every year, 268 million of those resulting in at least 3 days absence from work. ILO estimates the cost of work accidents & professional diseases indemnities and absences to 4% of the world GDP. 


Throughout the world, companies are starting to meet the workplace safety challenge with intensive ‘Go for Zero’-strategies, expressing their unwavering ambition to reduce workplace accidents. Brady, a worldwide manufacturer and supplier of Safety Solutions, supports ‘Go for Zero’-strategies with a broad range of quality products, including on-site printable safety signage, custom signs, pipe markers, spill control and Lockout/Tagout.

Source: Inventory of socioeconomic costs of work accidents, Joss Mossnik, Marc de Greef, 2002
Source from: Brady