Product Overview

Summary: This Lockout Tagout Safe Operating Procedure provides a clear, step-by-step method for safely isolating and de‑energising plant and equipment before any maintenance, cleaning or repair work. It helps Australian businesses prevent serious injuries and fatalities from unexpected start-up or stored energy release, while demonstrating compliance with WHS legislation and duty of care obligations.

Unexpected start-up of machinery or the uncontrolled release of stored energy remains one of the leading causes of serious workplace incidents in Australia. This Lockout Tagout Safe Operating Procedure (LOTO SOP) establishes a consistent, legally defensible process for isolating, locking and tagging plant and equipment before any servicing, maintenance, cleaning, fault-finding or setup work is carried out. It translates WHS legislative requirements and industry best practice into practical, easy-to-follow instructions tailored for Australian workplaces across manufacturing, warehousing, utilities, construction, and facilities management.

The procedure defines who is authorised to apply locks and tags, how to identify all energy sources (electrical, pneumatic, hydraulic, mechanical, thermal, gravitational and stored energy), and the verification steps required before work begins and after work is completed. It addresses common problem areas such as contractors bypassing isolation, shared equipment, shift handovers and group lockout arrangements. By implementing this SOP, businesses can significantly reduce the risk of amputations, crush injuries, electric shock and fatalities, while improving maintenance efficiency, strengthening safety culture and providing clear evidence of due diligence during audits, investigations and regulator visits.

Key Benefits

• Prevent serious injuries and fatalities by establishing a consistent, verified process for isolating hazardous energy sources.
• Ensure compliance with Australian WHS legislation and relevant Codes of Practice relating to plant, electrical safety and maintenance work.
• Standardise isolation practices across employees and contractors, reducing confusion, shortcuts and unsafe variations in procedure.
• Improve maintenance planning and downtime control through clear roles, responsibilities and communication protocols for lockout tagout activities.
• Provide defensible documentation and training material to support inductions, toolbox talks, contractor management and incident investigations.

Who is this for?

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

Hazards Addressed

• Unexpected start-up of machinery during maintenance or cleaning
• Release of stored mechanical energy (e.g. springs, elevated loads, tensioned belts and chains)
• Release of stored hydraulic or pneumatic pressure
• Contact with live electrical parts and electric shock
• Entanglement, crushing and amputation from moving parts
• Exposure to hazardous substances released during isolation or de‑isolation
• Failure to control multiple energy sources on complex plant
• Inadvertent removal of isolations by unauthorised persons
• Miscommunication during shift changeover or contractor work

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions (Lockout, Tagout, Isolation, Authorised Person, Competent Person, Group Lockout)
• 3.0 Roles and Responsibilities (PCBU, Officers, Supervisors, Workers, Contractors)
• 4.0 Applicable Legislation, Standards and Codes of Practice
• 5.0 Hazard Identification and Risk Assessment for Hazardous Energy
• 6.0 Required Lockout Tagout Equipment (Locks, Tags, Hasps, Isolation Devices, Key Management)
• 7.0 Pre-Job Planning and Communication Requirements
• 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 Handover, Permit Systems and Contractor Management
• 12.0 Removal of Locks and Tags, Return to Service and Post-Job Checks
• 13.0 Exceptions, Temporary Energisation and Testing Under Controlled Conditions
• 14.0 Training, Competency and Authorisation Requirements
• 15.0 Inspection, Audit and Continuous Improvement of LOTO Program
• 16.0 Recordkeeping, Forms and Sample Checklists
• 17.0 Emergency Procedures and Incident Response Related to Isolation Failures

Legislation & References

• Work Health and Safety Act 2011 (Cth and harmonised state/territory versions)
• Work Health and Safety Regulations 2011 – Part 4.1 Use of Plant
• 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
• AS/NZS 4836: Safe working on or near low-voltage electrical installations and equipment
• AS/NZS ISO 45001: Occupational health and safety management systems