LOTO Services

 Protecting your workers from hazardous energy

Every year, hundreds of Kiwi employees are seriously injured or killed by machinery. Fingers are caught in cogs, limbs are severed by blades, or a body is crushed by a press.

Many of these incidents occur because the machine was not properly locked out.

What is LOTO and what does stand for?   

LOTO stands for LOCK OUT, TAG OUT and is a set of established procedures that includes locks and tags for ‘locking out, tagging out’ each of the energy sources on a machine or machine.

LOTO requires a specific procedure to be followed and this can be different for each and every machine.  At a high level this will involve:

  1. Stopping the machine in a controlled manner.
  2. De-energising the energy sources so far as reasonably practicable
  3. Isolating energy sources and securing (Lock Out) this isolation in a safe state.
  4. Verifying/testing that the machine has been de-energised/isolated.
  5. Communicating the plant status to others (Tag Out).
Risk Management

Why Choose TEG’s Programme Management?

Why is LOTO necessary?

Every manufacturing workplace with machines should have a hazardous energy control programme in place. One of the most important features of this programme is LOTO.

  • LOTO safety is all about controlling hazardous energy during cleaning and maintenance processes.
  • A LOTO programme also involves training workers on the hazards of residual energy and lockout/tagout procedures, policies, and equipment. 
  • Ongoing monitoring and review of systems and plant is also required to maintain the effectiveness of the programme.

Why choose TEG’s LOTO Services?

TEG Risk has the specialist engineering professionals to evaluate your machinery to determine its energy sources and LOTO requirements and any residual risks.

Lock-out procedures should be clearly communicated and easily accessible. 

In our experience LOTO is not done well in practice and even if the procedures are documented they are buried away in a wordy Standard Operating Procedure that usually sits in a on a shelf somewhere ready to be pulled out at the next safety or quality audit.

A simple way for a workplace to improve on this practice is to have informative pictorial based placards at the machine. This is a practical way to provide a visual guide for workers especially when literacy or language is a potential issue.

 (LOTO) procedures are even easier with TEGRA, TEG Risk’s machine risk assessment app. TEGRA automates the LOTO process and can produce LOTO cards/placards for each machine. 

What We Offer


Clients who have already completed machine risk assessments by TEG Risk will be able to utilise insights through our machine safety app TEGRA. In the app will find most of the data and images are already available to produce the LOTO cards with little extra work required.


Alternatively, if organisations want just LOTO cards TEG simply carry out a LOTO assessment at each machine to produce the cards in a timely fashion.


Applying LOTO allows a company to minimise the risks associated with their machinery when it comes to cleaning, or the maintenance and repair of machinery.

Creating detailed LOTO cards means that your machines will have all the necessary information on the energy sources, instructional steps showing where the isolators are and how to secure them in the safe state. Providing this resource for your workplace will make it safer and more compliant.

Get in touch with our team if you are looking to get your LOTO process improved.