Title: Common Violations & Emergency Procedures
Type: Lesson
Most LOTO injuries occur because a procedure wasn’t followed, a step was skipped, or someone acted without authority. This lesson covers the most common violations and how to respond to emergencies involving LOTO.
Failure to identify all energy sources
Workers only shut off electrical power and forget hydraulic, pneumatic, or stored energy
Skipping verification
Equipment is not tested before work begins
Group lockout errors
One lock used for multiple workers, or locks removed before everyone is done
Removing someone else’s lock
Only the person who applied a lock can remove it — or a supervisor following formal written procedures
Using non-LOTO-approved devices
Zip ties, string, or duct tape are not acceptable substitutes
Unauthorized restart
Someone re-energizes equipment without checking that all locks are removed and the area is clear
If an emergency occurs during a LOTO situation:
Stop work immediately
Call for help or activate your site’s emergency protocol
Do not remove or alter any locks or tags unless authorized
Only a supervisor (with documentation and verification) may remove another worker’s lock in emergency cases
Secure the area until the hazard is contained and equipment can be inspected
This must be done only if:
The authorized employee is not at the facility
All efforts to locate them have failed
A written procedure is followed
The worker is notified before resuming work
LOTO is not optional — it’s a legal and life-saving requirement. Shortcuts, assumptions, and unauthorized actions are the leading causes of fatal accidents during equipment service.
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