Sequence of Lockout Toolbox Talk

Lock out tag out has to be done in the right order. Skipping a step, rushing the shutdown, or testing equipment too soon can leave workers exposed to moving parts, electrical shock, pressure release, stored energy, or unexpected startup. The sequence matters because each step protects the next one.

This talk focuses on the basic sequence of lockout before service, repair, cleaning, adjustment, or jam clearing begins. The crew needs to understand how to prepare, shut down, isolate, lock, release stored energy, verify zero energy, and keep the equipment controlled until the work is complete.

Why This Matters

• A clear lockout sequence prevents missed steps and unsafe shortcuts.
• Shutting equipment off is not the same as isolating hazardous energy.
• Stored energy can remain after the machine is stopped and locked out.
• Verification confirms the equipment cannot start, move, pressurize, heat up, or energize.
• Following the same order every time helps crews work safely across shifts and trades.

Common Hazards

• Starting work after hitting a stop button without isolating the energy source.
• Locking the wrong breaker, valve, disconnect, plug, or switch.
• Failing to notify affected workers before shutdown or lockout begins.
• Leaving hydraulic, pneumatic, electrical, gravity, mechanical, thermal, or chemical energy stored in the system.
• Skipping the try-start or verification step before placing hands or tools into the equipment.
• Removing locks before guards, covers, tools, and workers are clear.
• Re-energizing equipment without warning nearby crews or other trades.
• A control circuit shutting down the machine while a separate power feed, battery, generator, or pressure line remains active.

Safety Checklist

Before Work Begins

• Review the equipment-specific lock out tag out procedure.
• Identify all energy sources, including electrical, hydraulic, pneumatic, mechanical, gravity, thermal, chemical, and stored energy.
• Notify affected workers that equipment will be shut down and locked out.
• Shut the equipment down using the normal stop or shutdown controls.
• Isolate each energy source at the correct breaker, disconnect, valve, plug, switch, block, or control point.
• Apply personal locks and tags to each required energy-isolating device.
• Release, bleed, block, pin, lower, discharge, or restrain stored energy.
• Verify zero energy by testing controls and confirming the equipment cannot start or move.

During Work

• Keep locks and tags in place for the full length of the task.
• Do not bypass a lockout step because the job appears simple or quick.
• Watch for energy building back up in lines, tanks, cylinders, springs, or heated parts.
• Stop and restart the sequence if a new energy source is found.
• Use group lockout procedures when more than one authorized worker is exposed.
• Communicate clearly during breaks, shift changes, and crew handoffs.
• Before re-energizing, make sure tools are removed, guards are replaced, workers are clear, and affected workers are notified.

Crew Talking Points

• What is the lockout sequence for the equipment we are working on today?
• Have all energy sources been identified before shutdown?
• Who needs to be notified before the equipment is locked out?
• How will stored energy be released, blocked, or controlled?
• How will we verify zero energy before starting the work?
• Does anyone have a question or concern about any step in the lockout sequence before we begin?

Stop Work If

• The equipment-specific lockout procedure is missing, unclear, or does not match the setup.
• An energy source cannot be identified, isolated, locked, or controlled.
• Stored energy has not been released, blocked, or restrained.
• The equipment starts, moves, cycles, leaks, sparks, heats up, or builds pressure during verification.
• A lock, tag, valve, breaker, disconnect, plug, or switch is missing, damaged, or unclear.
• Workers are unsure whether the lockout sequence has been completed in the correct order.

Final Reminder

Do lockout in order every time: prepare, notify, shut down, isolate, lock and tag, control stored energy, verify zero energy, then start the work.