Lockout/tagout procedure template: what a machine-specific procedure must include
Most free lockout/tagout templates are a single page that says “shut it off, lock it, try to start it.” That's a fine outline, but OSHA expects more than an outline. The standard asks for a documented procedure that tells an employee how to control the hazardous energy on a specific machine. This guide covers what that procedure must contain, shows a worked example, and lists the mistakes that get procedures cited.
What 1910.147(c)(4)(ii) requires
The standard says energy control procedures must clearly and specifically outline the scope, purpose, authorization, rules and techniques employees use to control hazardous energy, and how compliance is enforced. At a minimum each procedure includes:
| Paragraph | Required content | What it looks like in practice |
|---|---|---|
| (c)(4)(ii)(A) | A specific statement of the intended use of the procedure | “Lockout of the 200-ton hydraulic press HP-01 for die changes, cleaning and maintenance.” |
| (c)(4)(ii)(B) | Specific steps to shut down, isolate, block and secure the machine | Normal stop, then each isolation point by name and location, then blocking of the ram. |
| (c)(4)(ii)(C) | Specific steps to place, remove and transfer lockout/tagout devices, and who is responsible for them | Each authorized employee applies a personal lock to each point (or the group box). Only they remove it. Shift-change handoff. |
| (c)(4)(ii)(D) | Specific requirements for testing the machine to verify that lockout is effective | Try-start at the controls, meter test for absence of voltage, gauges at 0 psi. |
The energy source table
The fastest way to make a procedure specific is a table with one row per energy source. Give each isolation point an ID (E-1 for the first electrical source, P-1 for pneumatic and so on) and use the same ID on the placard, in the steps and on a tag at the device itself.
| Tag | Energy & magnitude | Isolation device & location | Lockout device |
|---|---|---|---|
| E-1 | Electrical, 480 VAC 3-phase | Disconnect DS-14, column C3 | Padlock on disconnect handle |
| H-1 | Hydraulic, 3,000 psi | Hydraulic isolation valve, pump unit | Ball valve lockout + padlock |
| G-1 | Gravity, raised ram | Ram locking pin | Lockable safety block |
Don't forget energy that isn't obvious: accumulators, capacitors in drives, compressed air trapped in cylinders, springs, flywheels, raised loads, steam and hot surfaces, and chemicals in lines.
The step sequence
Paragraph (d) of the standard gives the order. Write your steps in this sequence:
- Prepare: the authorized employee knows the type and magnitude of each energy source, its hazards and how to control it.
- Notify affected employees.
- Shut down with the normal stopping procedure.
- Isolate each energy source at its energy isolating device. Push buttons and selector switches don't count.
- Apply locks and tags to each isolation point.
- Release or restrain stored energy: bleed, drain, block, discharge, lower to rest.
- Verify isolation: make sure people are clear, try to start, test, then return controls to off.
Then the release-from-lockout steps from paragraph (e): remove tools, reinstall guards, clear and notify employees, and have each employee remove only their own lock.
When you don't have to write a procedure
The note to 1910.147(c)(4)(i) lets you skip documenting a procedure for a particular machine only when all eight of these are true:
- It has no potential for stored or residual energy, or for energy to re-accumulate after shutdown, that could endanger employees.
- It has a single energy source that can be readily identified and isolated.
- Isolating and locking out that source completely de-energizes and deactivates it.
- It is isolated from that source and locked out during the servicing or maintenance.
- A single lockout device achieves the locked-out condition.
- That lockout device is under the exclusive control of the authorized employee doing the work.
- The servicing or maintenance doesn't create hazards for other employees.
- You have had no accidents involving unexpected activation or re-energization of that machine during servicing or maintenance.
Most production machines fail at least one of these, usually stored energy or multiple sources. When in doubt, write the procedure.
Can one procedure cover several machines?
Yes, when the machines really are the same: the same type and magnitude of energy, and the same or similar isolation devices and steps. A row of identical bench grinders can share a procedure. A press line with different disconnect locations cannot share one generic sheet.
Common mistakes
- Too generic. “Turn off power at the disconnect” without saying which disconnect, or where.
- Control circuits listed as isolation. An E-stop or start/stop button is not an energy isolating device.
- Stored energy skipped. No step for bleeding air, dumping the accumulator or blocking a raised load.
- No verification. Locks on, but nobody tries to start the machine or tests for voltage.
- Never reviewed. The machine was rewired or re-plumbed and the procedure wasn't updated, and the annual inspection never happened.
Frequently asked questions
Is there an official OSHA lockout/tagout procedure template?
No. OSHA publishes the required content in 29 CFR 1910.147(c)(4)(ii) and a sample minimal procedure in Appendix A of the standard, but the procedure must be filled in with the details of your specific machine.
How long should a lockout procedure be?
Long enough to be specific. For most machines one page is enough: an energy source table plus the numbered steps. Complex equipment with many energy sources may need two.
Who should write lockout procedures?
Someone who knows the machine, usually a maintenance lead or authorized employee, reviewed by whoever runs your safety program. Walk the machine and confirm every isolation point in person.
Skip the blank template
LotoSmith turns each machine's energy sources into a machine-specific procedure, a color-coded placard, isolation-point tags, and the written program, inspection and training forms. Build free in your browser. Clean copies are $49 once.
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This guide summarizes 29 CFR 1910.147 for general information. It is not legal advice. Read the standard itself, and check any state-plan or provincial rules that apply to you.