Lockout/Tagout (LOTO): The Complete Buyer's Guide (2026)

Lockout/Tagout (LOTO): The Complete Buyer's Guide (2026)

Lockout/Tagout (LOTO) is the OSHA-mandated procedure for isolating machinery and equipment from hazardous energy before service or maintenance work, governed by OSHA 29 CFR 1910.147. For most maintenance teams the starting point is a keyed-different lockout padlock assigned to one authorized employee — our default recommendation is the Brady SafeKey aluminum lockout padlock, with a TradeSafe 10-pack keyed-alike set for equipping a full team and a QWORK cable lock for irregularly shaped isolation points. This guide explains the 6-step LOTO procedure, energy source types, device categories, and how to build a compliant program, so you leave knowing exactly what to buy.

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What is lockout/tagout?

Lockout/Tagout (LOTO) is the set of procedures and devices used to isolate equipment from its energy sources and physically lock that isolation in place before anyone performs service or maintenance, so the machine cannot be unexpectedly re-energized or start up while someone is exposed to it. It is governed in general industry by OSHA 29 CFR 1910.147, and it exists specifically to prevent injuries from the unexpected energization or start-up of machinery during servicing.

What Is Lockout Tagout (LOTO)?

See What Is Lockout Tagout (LOTO)? for the full plain-language explainer this pillar builds on. In short: lockout physically locks an energy-isolating device (a valve, breaker, or disconnect) in the off position; tagout adds a warning tag. OSHA treats lockout as the primary method and tagout as a secondary or supplemental measure where a lock cannot be physically applied.

Who needs a LOTO program

Any workplace with machinery, electrical panels, piping, or equipment that stores hazardous energy and requires periodic service, repair, or cleaning needs a documented LOTO program — manufacturing, utilities, food processing, and facilities maintenance are the most common settings. Note that 1910.147 explicitly excludes some situations, such as work on cord-and-plug-connected equipment where unplugging the cord and keeping it under the exclusive control of the employee performing the work fully removes the energy hazard, and construction work covered separately under 1926 subpart K for electrical and other construction-specific standards. Confirm which standard applies to your specific work before assuming general-industry 1910.147 governs it.

Hazardous energy sources

LOTO is not limited to electrical power. OSHA 1910.147 covers all forms of hazardous energy that must be isolated before service work begins.

Electrical

The most familiar form — breakers, disconnects, and plugs isolated and locked in the off position before work on electrical equipment.

Mechanical, hydraulic & pneumatic

Stored mechanical energy (springs, counterweights, raised components), pressurized hydraulic fluid, and compressed air/pneumatic systems all need to be relieved or blocked, not just powered off, since residual stored energy can move a component even after the power source is isolated.

Thermal & chemical

Steam, hot process fluids, and chemical feed lines require isolation (often via plug lockouts or valve lockouts on the supply line) in addition to or instead of electrical lockout, depending on the equipment. Thermal hazards also include equipment that remains hot well after power is removed, which is why a written procedure should specify a cool-down period alongside the isolation step rather than treating "powered off" as "safe to touch."

The OSHA 6-step LOTO procedure

How to Perform Lockout/Tagout walks through OSHA's 6-step energy-control procedure in full; the summary below is the sequence every authorized employee should follow.

1. Prepare for shutdown

Identify all energy sources feeding the equipment and review the equipment-specific written procedure before touching anything.

2. Notify and shut down

Notify affected employees, then shut the equipment down using its normal stopping procedure.

3. Isolate the energy source

Operate the energy-isolating device (breaker, valve, disconnect) so the equipment is completely disconnected from every identified energy source.

4. Apply lockout/tagout devices

Apply a personal padlock such as the Brady SafeKey lockout padlock to each isolating device, with a tag identifying the employee and the reason for lockout.

5. Relieve stored energy

Bleed, block, or otherwise render safe any residual or stored energy (springs, capacitors, pressurized lines, raised components) that the isolation step alone did not eliminate.

6. Verify isolation

Confirm the equipment cannot be operated after taking steps to ensure personnel are safely positioned away from the equipment, then attempt to start the equipment through its normal controls to verify it will not operate before beginning service work.

Lockout device categories

Different isolation points call for different lockout hardware. WC Safety stocks keyed padlocks, cable locks, hasps, tags, plug lockouts, and pre-built lockout stations covering the full device landscape a complete LOTO program needs — see How to Choose a Lockout/Tagout Padlock for selection guidance.

Lockout padlocks

The core device: a padlock assigned to one authorized employee, keyed either uniquely (one key per lock) or alike (one key fits a set, useful for a single crew). The Brady SafeKey and lockout padlocks collection cover individual keyed-different locks, while the TradeSafe 10-pack covers keyed-alike team sets.

Cable lockouts

A cable lockout threads a flexible steel cable through multiple isolation points (valve handles, breaker panels, irregularly shaped equipment) that a rigid padlock shackle cannot reach directly. The QWORK cable lock 4-pack, the single 6ft TRADESAFE adjustable cable lock, and the 8-pack QWORK cable lock cover this use case in the cable lockouts collection.

Lockout hasps

A hasp lets multiple employees each apply their own padlock to a single isolation point — the hardware that makes group lockout physically possible. The BULANGDI aluminum hasp (10-pack) and BOZZYS 6-hole steel hasp (6-pack) cover the lockout hasps collection.

LOTO tags

Tags document who applied a lock and why, supplementing (not replacing) a physical lock. The TRADESAFE Danger Do Not Operate tags (30-pack) and Master Lock 497A laminated tags (12-pack) cover the LOTO tags collection.

Plug lockouts

A plug lockout device encloses a cord-and-plug connection so it cannot be re-inserted while locked, covering the 1910.147 exception for cord-and-plug equipment where the plug stays under the servicing employee's exclusive control. The TRADESAFE 110-125V plug lockout and QWORK 2 & 3-prong plug lockout (2-pack) cover the plug lockouts collection.

Lockout stations

A wall-mounted lockout station centralizes padlocks, hasps, and tags for a whole facility or department in one lockable board, useful for standing up a program quickly. The TRADESAFE 14-piece station and TAEGIQI 4-lock station cover the lockout stations collection.

Personal LOTO kits

A compact personal kit like the Brady 123143 compact personal safety kit bundles a padlock with tags and basic accessories for an individual authorized employee to carry, rather than sourcing each piece separately.

Lockout vs. tagout: which do you need?

Lockout vs. Tagout: What's the Difference? covers this in depth. In brief: lockout (a physical lock preventing operation) is the OSHA-preferred method wherever the energy-isolating device is capable of being locked. Tagout (a warning tag with no physical lock) is only permitted where the device has no provision for a lock, and when used alone requires additional employee protection measures beyond the tag itself, since a tag alone does not physically prevent re-energization.

Group lockout & multi-employee jobs

When more than one crew or trade is working on the same equipment, OSHA requires a group lockout procedure that gives each authorized employee the same protection as an individual lock — typically through a lockout hasp allowing multiple padlocks on a single isolation point, or a group lockbox where individual keys are secured until every employee has removed their lock. This ensures no single person can re-energize equipment while any other crew member is still exposed.

Written program & training requirements

OSHA 1910.147 requires a written energy-control program specific to your equipment, periodic inspection of that program (at least annually), and training for both authorized employees (who perform lockout) and affected employees (who operate or work near locked-out equipment but do not perform the lockout themselves). See What Is Lockout Tagout? for the training-role breakdown.

Inspecting and maintaining lockout devices

A lockout padlock that has corroded, cracked, or lost its key is a compliance gap waiting to be discovered mid-shutdown. Inspect padlocks, cables, and hasps periodically for a shackle that no longer seats fully, a body that has been forced or pried, or a key that has been duplicated outside the program's control. Keep a log of which employee is assigned which serialized lock so a lost key or damaged device can be traced and replaced without disrupting an active lockout elsewhere in the facility.

LOTO and machine guarding are not interchangeable

A fixed guard or interlock that prevents contact with a hazard during normal operation is a different control than lockout/tagout, which isolates energy during service and maintenance when guards are removed or bypassed. Many incidents happen specifically because a guard was removed for maintenance and the equipment was not also locked out — the two controls work together, not as substitutes for each other.

Writing equipment-specific procedures

A generic "lock it out" instruction is not sufficient under 1910.147 — each piece of equipment (or each family of substantially similar equipment) needs its own written procedure identifying its specific energy sources, the exact isolating devices to operate, and the method used to verify isolation on that machine. A punch press and a conveyor motor do not share a lockout procedure even if both use the same style of padlock, because the isolation points, stored-energy risks, and verification steps differ. Building this documentation is usually the longest step in standing up a new program, well beyond simply buying padlocks.

How to choose LOTO devices by use case

Match the device to the isolation point and crew size, not just the cheapest padlock available.

Individual maintenance technician

A single keyed-different padlock like the Brady SafeKey assigned personally to one authorized employee is the baseline. CHECK PRICE ON AMAZON →

Full maintenance crew

A keyed-alike 10-pack such as the TradeSafe 10-pack or TradeSafe yellow 10-pack equips an entire team economically while still giving each member their own assigned lock.

Valves & irregular isolation points

A cable lockout like the QWORK cable lock 4-pack threads through multi-point valve handles or equipment a rigid padlock cannot directly shackle.

Starting a new LOTO program

A personal kit such as the Brady 123143 is a low-friction way to get individual employees outfitted while a broader written program and hasp/tag infrastructure is being built out.

Comparison table: lockout padlocks

The table below spans individual and team-set padlocks plus cable and kit formats. Prices are indicative and subject to change.

As an Amazon Associate, WC Safety earns from qualifying purchases. Prices and availability are accurate as of the date shown and subject to change. Full affiliate disclosure.

Recommended LOTO devices

These four cover the range most buyers need — an individual keyed-different padlock, a team keyed-alike set, a cable lock for irregular points, and a personal starter kit. All are stocked at WC Safety.

Brady SafeKey Aluminum Padlock — Best individual lockout padlock

Brady · $23.29

A keyed-different aluminum lockout padlock assigned to one authorized employee, the standard building block of any LOTO program. See it on the Brady SafeKey Aluminum Padlock.

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TradeSafe 10-Pack Lockout Locks — Best for equipping a full crew

TRADESAFE · $59.95

A keyed-alike 10-pack that outfits an entire maintenance team economically while keeping locks individually assigned. See it on the TradeSafe 10-Pack Lockout Locks.

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QWORK Cable Lockout (4-Pack) — Best for valves and irregular points

QWORK · $17.97

A flexible steel cable lockout that threads through multi-point valves and equipment a rigid padlock cannot reach. See it on the QWORK Cable Lockout (4-Pack).

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Brady 123143 Personal LOTO Kit — Best for new program buildout

Brady · $11.95

A compact personal kit bundling a padlock with tags, a low-friction way to get individual employees outfitted quickly. See it on the Brady 123143 Personal LOTO Kit.

VIEW ON WC SAFETY →CHECK PRICE ON AMAZON →

As an Amazon Associate, WC Safety earns from qualifying purchases. Prices and availability are accurate as of the date shown and subject to change. Full affiliate disclosure.

Lockout/tagout: frequently asked questions

Related lockout/tagout guides & pages

• What Is Lockout Tagout (LOTO)? OSHA 1910.147 Explained
• Lockout vs. Tagout: What's the Difference?
• How to Perform Lockout/Tagout: The OSHA 6-Step Procedure
• How to Choose a Lockout/Tagout Padlock
• Best Lockout Tagout Kits · Best Lockout Tagout Padlocks
• Lockout/tagout collection · Lockout padlocks collection