Lockout/Tagout Compliance Checklist (Program, Procedure, Field)
Use this checklist to find the gaps in your lockout/tagout program before an OSHA inspector or an incident does. It is organized into four levels: the program, the procedures, the field execution, and the annual audit. Anything unchecked is a priority to close.
Program-level checklist
Your foundation — confirm that:
- A written energy control program exists and matches reality
- Every machine requiring LOTO is inventoried
- Lockout devices are standardized, durable, and identifiable by color or shape
- Tags use the same format and warning wording everywhere
- Authorized, affected, and other employees are trained appropriately
- Training records are current and retrievable
- Shift-change, contractor, and group lockout rules are documented
Procedure-level checklist
For each machine-specific procedure, verify:
- All energy sources are identified with type and magnitude
- Every isolation point is named exactly (panel, breaker, valve, plug)
- The lockout device for each point is specified
- Stored and residual energy release steps are explicit
- A verification (try-start) step is included
- Photos of isolation points are included
- The procedure has been reviewed with the employees who use it
- The procedure is accessible at the point of work
Field execution checklist
Every time work happens, confirm:
- Affected employees were notified before shutdown
- The machine was shut down using its normal stopping method
- Every energy source was isolated and locked, not just the obvious one
- Stored energy was released, blocked, or restrained
- Zero energy was verified before hands went in
- Each worker applied a personal lock — no shared locks
- Locks are removed only by their owners after work is complete
Annual audit checklist
Once per year, for every procedure:
- A periodic inspection was performed by an authorized employee who does not use the procedure
- Deviations were identified and corrected
- The certification names the equipment, date, employees, and inspector
- Authorized employees were reviewed on their responsibilities
- Affected employees were reminded of the prohibitions
Key takeaways
- Four layers to audit: program, procedures, field execution, annual inspections.
- Exact isolation points and verification steps are the details auditors check first.
- Personal locks for every worker — no shared locks, ever.
- Keep the checklist alive: use it quarterly, not once a decade.
Frequently asked questions
How often should we run this checklist?
A full pass quarterly is a realistic target for most plants, with the annual inspection section verified continuously as certifications come due. After any equipment modification or LOTO near-miss, re-run the relevant sections immediately.
What should we fix first if everything fails?
Machine-specific procedures for the highest-risk, most-serviced equipment. It is the most-cited gap and the fastest path to reduced risk — then close the verification and stored-energy gaps in the field.
Manage lockout/tagout procedures digitallyTegis Safety keeps procedures current and audit-ready.
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