Machinery with electrical, mechanical, or hydraulic energy creates risk if not fully isolated before maintenance. Workers face shock, pressure release, or crush injuries during routine tasks like servicing, filter replacement, or inspection.
Incidents often occur when equipment is switched off but not locked. Another person may restart it, or energy may remain stored in the system. Shared isolation points and unclear procedures increase this risk. Without a lockout tagout system, workers rely on verbal instructions or memory, which leads to errors.
A lockout tagout policy provides a fixed process for isolating energy. Each point is identified, locked with a physical device, and tagged with the worker’s name. The system stays in place until the task is complete and all energy is discharged. This reduces the chance of accidental restarts, supports compliance with WHS laws, and improves internal safety checks.
What Lockout Tagout Involves
Lockout tagout is a control method used to isolate machinery and energy sources during repair or maintenance. A lockout device physically keeps equipment switched off. A tag is added to warn that the equipment must not be used. This prevents workers from being exposed to stored or active energy.
The process may involve isolating electrical circuits, turning off valves, or releasing stored pressure. The system stays in place until the person performing the work removes their own lock. This ensures that no one else can restart the equipment by mistake. Lockout tagout is used in mechanical, electrical, hydraulic, and chemical environments where energy isolation is essential.
Lower Risk and Injury Across All Work Areas
Lockout tagout helps stop machines from starting up while people are working on them. Sudden movement, electrical surges, or pressure buildup can cause broken bones, burns, or amputations. A clear isolation system ensures workers are not exposed to these hazards.
Each step of the policy removes energy at the source. This covers switches, pipes, stored power, and moving parts. When done correctly, it supports a safer process for repair and servicing. It also lowers the risk of mistakes between shifts or when more than one person is working on the same system.
Meet Australian WHS Compliance
Work health and safety laws require duty holders to manage risks related to plant and energy. In Australia, Safe Work codes outline specific duties to control hazardous energy during servicing. Lockout tagout is often the preferred method, especially in high-risk sectors.
A workplace without an isolation system may fail to meet WHS obligations. This can result in legal action, stop-work notices, or liability in case of injury. A lockout tagout policy shows clear steps for energy isolation and who is responsible. It also supports audit tracking and risk control.
Improve Maintenance Without Delays
A lockout tagout system gives structure to shutdowns and repair tasks. Workers know exactly what to do, who is involved, and when equipment is safe to access. This reduces downtime caused by confusion or waiting on approvals.
Clear instructions allow teams to work faster without cutting corners. Lockout logs and procedures also help prevent rework. Common issues like accidental resets or partial shutdowns are avoided. This leads to faster repairs, fewer system faults, and better use of staff time.
Ensure Training Matches Actual Risk
Training is a key part of any lockout tagout system. It is not enough to hand out locks and tags. Each worker must understand what energy types apply to their role and how to follow the steps. Inductions, toolbox talks, and repeat sessions are needed to keep everyone up to date.
Training also applies to contractors, shift workers, and team leaders. Procedures must reflect current tasks, not outdated manuals. Visual instructions, language support, and real examples make the system easier to follow and apply.
Management Responsibility and Oversight
Managers are responsible for setting up and monitoring lockout tagout procedures. This includes checking that equipment has isolation points, keeping lock supplies stocked, and reviewing incident reports. Supervisors must also make sure policies are followed in daily work.
Ongoing support matters. If procedures are unclear or locks are missing, people may skip steps. Management must respond fast to fix gaps. Spot checks, sign-off sheets, and formal audits support better outcomes and improve long-term compliance.
Avoid the High Cost of Incidents
Missing or incomplete lockout systems lead to avoidable incidents. These can cause injury, machine damage, and unplanned downtime. Sites may face insurance increases, claim costs, or formal investigations.
The cost of one major event often outweighs what’s needed to build a working setup. A basic system includes
- padlocks for individual control
- warning tags with name and contact
- hasps for shared lock points
- lockout devices for switches and valves
- a station to store and track gear
These products support safe isolation and reduce the risk of errors. One working system can prevent high-cost incidents and meet safety requirements without delay.
On-Site Support from Locksafe
Sites with electrical panels, hydraulic lines, or pressurised systems must isolate energy during service work to meet WHS regulations. Missing locks, shared access, or unclear steps can lead to serious injury, equipment faults, or regulatory breaches.
Locksafe supplies lockout kits for switchboards, valve lockouts, cable hasps, and isolation tags that match Australian machinery standards. We help identify missing lock points, supply system-specific gear, and assist with setting up multi-user lock procedures.
Our team works with safety coordinators and maintenance staff to ensure each lockout step is followed with the correct equipment. Contact us for more information.
Frequently Asked Questions
How often should lockout tagout training be refreshed?
At least once a year or after any major incident, new equipment installed, or change in staffing. Refresher training helps maintain compliance and awareness.
What types of energy should be locked out?
Electrical, hydraulic, pneumatic, chemical, thermal, and stored mechanical energy must all be considered depending on the system in use.
Do tagout systems alone meet legal safety requirements?
In most cases, no. Tags are a warning only. Physical lockout is required unless the system cannot be locked, in which case extra steps are needed.
Are there industry-specific lockout tagout rules in Australia?
Yes. Sectors like mining, food processing, and manufacturing may have added requirements under their WHS regulators.
Can a single lock be used by multiple workers?
No. Each worker must apply their own lock to ensure personal safety. Group lockout devices can be used when several people are involved.
