Product Overview

Summary: This Equipment Lockout Tagout Safe Operating Procedure provides a clear, step‑by‑step system for isolating, locking and tagging machinery and plant before any maintenance, cleaning or repair work. It helps Australian workplaces prevent unexpected start‑up, stored energy releases and serious injuries, while demonstrating due diligence under WHS legislation.

Uncontrolled energy is one of the most serious risks in any workplace that uses machinery, plant or powered equipment. This Equipment Lockout Tagout Safe Operating Procedure sets out a structured, repeatable approach to isolating and securing equipment before anyone works on it. It defines who is responsible, what isolation devices must be used, how to verify zero energy, and how to manage multiple workers or contractors on the same task. The SOP is written specifically for Australian workplaces and aligns with WHS obligations around plant, electrical safety and safe systems of work.

By implementing this procedure, businesses reduce the risk of unexpected start‑up, stored energy release, electrical shock and entanglement incidents that can lead to life‑altering injuries or fatalities. It also addresses common gaps found during regulator inspections and internal audits, such as inconsistent isolation practices, undocumented permissions, and poor control of keys and tags. The document supports training, contractor management and incident prevention across manufacturing, construction, utilities, facilities management and other plant‑intensive operations, helping organisations demonstrate compliance, protect workers and maintain productivity.

Key Benefits

• Prevent unexpected energisation and start‑up of machinery during maintenance, cleaning and repair activities.
• Reduce the likelihood of serious injuries and fatalities associated with electrical shock, entanglement and stored energy release.
• Standardise isolation practices across sites, shifts and contractors to ensure consistent, auditable compliance with WHS duties.
• Support effective training and competency assessment for workers required to isolate, lock and tag plant and equipment.
• Demonstrate due diligence to regulators, clients and insurers through a documented, defensible lockout tagout process.

Who is this for?

• WHS Managers
• Maintenance Supervisors
• Electrical Supervisors
• Site Managers
• Plant Operators
• Mechanical Fitters
• Electricians
• Production Managers
• Health and Safety Representatives (HSRs)
• Facilities Managers

Hazards Addressed

• Unexpected start‑up of machinery or plant during maintenance or cleaning
• Release of stored mechanical energy (springs, elevated loads, moving parts)
• Release of stored hydraulic or pneumatic energy in hoses, cylinders and lines
• Electrical shock or arc flash from energised circuits or equipment
• Contact with moving parts leading to entanglement, crushing or amputation
• Uncontrolled release of thermal energy (hot surfaces, steam, heated fluids)
• Exposure to hazardous substances released when equipment is opened or depressurised
• Unauthorised removal of locks or tags by untrained or uninformed personnel

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Lockout, Tagout, Isolation, Zero Energy, Competent Person)
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and References
• 5.0 Required Tools, Lockout Devices and Personal Protective Equipment (PPE)
• 6.0 Pre‑Isolation Planning and Risk Assessment
• 7.0 Identification of Energy Sources (Electrical, Mechanical, Hydraulic, Pneumatic, Thermal, Chemical, Gravitational)
• 8.0 Step‑by‑Step Lockout Tagout Procedure
• 9.0 Verification of Isolation and Zero Energy State
• 10.0 Group Lockout and Multiple Worker Procedures
• 11.0 Shift Change, Handover and Contractor Management
• 12.0 Removal of Locks and Tags, Return to Service
• 13.0 Management of Exceptions and Non‑Routine Tasks
• 14.0 Training, Competency and Authorisation Requirements
• 15.0 Inspection, Audit and Continuous Improvement
• 16.0 Recordkeeping and Documentation
• 17.0 Emergency Procedures and Incident Response
• 18.0 Review and Revision History

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state and territory laws)
• Work Health and Safety Regulations 2011 – Part 4.2: Duties of persons conducting businesses or undertakings involving plant
• Safe Work Australia – Code of Practice: Managing the Risks of Plant in the Workplace
• Safe Work Australia – Code of Practice: Managing Electrical Risks in the Workplace
• AS/NZS 4024.1603: Safety of machinery – Design of controls, interlocks and guards – Prevention of unexpected start‑up
• AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment
• AS/NZS ISO 45001: Occupational health and safety management systems – Requirements with guidance for use