Product Overview

Summary: This Lockout Tagout (LOTO) Safety Safe Operating Procedure provides a clear, step-by-step method for isolating and de-energising plant and equipment before maintenance, cleaning or repair. Tailored to Australian WHS requirements, it helps prevent serious injuries and fatalities caused by unexpected start-up, stored energy release or uncontrolled movement of machinery.

Unexpected start-up of machinery or the sudden release of stored energy remains one of the leading causes of serious workplace incidents in Australia. This Lockout Tagout (LOTO) Safety Safe Operating Procedure provides a robust, legally defensible framework for isolating, locking and tagging plant and equipment before any maintenance, cleaning, inspection or fault-finding work takes place. It translates WHS legislative duties and Australian Standards into practical, easy-to-follow steps that can be applied consistently across workshops, factories, warehouses and field service environments.

The procedure clearly defines responsibilities, required permits, isolation points, lock types and tagging protocols, as well as verification checks to ensure all energy sources are fully controlled. It also addresses complex isolations, group lockout arrangements and contractor management, which are common pain points for organisations. By implementing this SOP, businesses can significantly reduce the likelihood of crush injuries, amputations, electric shock and other catastrophic events, while demonstrating due diligence to regulators, clients and workers alike.

Designed specifically for the Australian context, the document aligns with Safe Work Australia guidance and state and territory WHS regulations. It supports businesses in creating a consistent, auditable LOTO system that integrates with existing risk management processes, training programs and permit-to-work systems, helping to build a strong safety culture around plant isolation and maintenance activities.

Key Benefits

• Reduce the risk of serious injuries and fatalities caused by unexpected energisation or movement of plant.
• Ensure compliance with Australian WHS legislation and relevant standards for isolation of plant and equipment.
• Standardise lockout tagout practices across sites, shifts and contractors for consistent, repeatable control.
• Strengthen evidence of due diligence in the event of an incident investigation or regulator inspection.
• Improve maintenance efficiency by providing clear, step-by-step isolation and re-energisation instructions.

Who is this for?

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

Hazards Addressed

• Unexpected start-up or energisation of machinery during maintenance or cleaning
• Release of stored mechanical, hydraulic, pneumatic, thermal or gravitational energy
• Electric shock and arc flash from live electrical work or incomplete isolation
• Crush injuries, amputations and entanglement in moving parts
• Exposure to hazardous substances released during uncontrolled equipment operation
• Uncontrolled movement of vehicles, mobile plant or equipment
• Inadvertent removal of isolations by unauthorised personnel
• Confusion or miscommunication during group or multi-disciplinary maintenance tasks

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Lockout, Tagout, Isolation, Stored Energy, Competent Person)
• 3.0 Roles and Responsibilities
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Pre-Task Planning and Risk Assessment Requirements
• 6.0 Lockout Tagout Equipment and Identification Requirements
• 7.0 Step-by-Step Lockout Tagout Procedure for Single-Person Tasks
• 8.0 Group Lockout and Multi-Disciplinary Isolation Procedures
• 9.0 Verification of Isolation and Stored Energy Dissipation
• 10.0 Re-energisation and Return-to-Service Procedure
• 11.0 Management of Contractors and Visitors During LOTO Activities
• 12.0 Special Considerations (Mobile Plant, Remote Isolations, Complex Systems)
• 13.0 Training, Competency and Authorisation Requirements
• 14.0 Inspection, Audit and Continuous Improvement of LOTO System
• 15.0 Recordkeeping, Tags, Logs and Permit-to-Work Integration
• 16.0 Incident Reporting, Non-Conformance and Corrective Actions
• 17.0 Review and Document Control

Legislation & References

• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS Acts
• Work Health and Safety Regulations 2011 (Cth) – Plant and Electrical Safety provisions
• Safe Work Australia – Code of Practice: Managing 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