Example only. Your machine's energy sources, isolation points and stored energy will differ; check the manufacturer's manual and walk the machine before writing your procedure.
Header
| Procedure no. | LOTO-014 (example) |
| Machine | Hydraulic press brake, 175 ton, asset PB-03, Bay 2 |
| Intended use (c)(4)(ii)(A) | Tooling changes, clearing jammed parts, backgauge adjustment and preventive maintenance |
| Authorized employees | Maintenance technicians, trained tool setters |
| Affected employees | Press brake operators, Bay 2 lead |
| Specific hazards | Ram can descend under gravity; accumulator holds pressure after pump stop; backgauge motors |
Energy sources and isolation points
| # | Energy | Magnitude | Isolation device | Lockout method | Stored energy | Verify |
|---|---|---|---|---|---|---|
| E1 | Electrical | 480 V AC, 3-phase | Main disconnect DS-3, wall left of machine | Padlock on handle in OFF | None after isolation (check capacitors per drive manual) | Try START; zero-voltage test at load side with a tested meter |
| E2 | Hydraulic | Up to system pressure on nameplate | Pump isolation valve V-1 | Valve lockout device | Accumulator: bleed via valve V-2 to tank | Gauge PG-1 reads 0 |
| E3 | Gravity | Ram and upper tooling weight | Mechanical: safety blocks under ram | Blocks in place, tagged | Ram resting on blocks | Visual: ram seated on blocks |
| E4 | Pneumatic | Shop air, 90 psi (backgauge clamps) | Ball valve AV-1 on drop | Ball valve lockout | Exhaust via dump valve | Gauge reads 0; clamps free |
Lockout sequence
- Prepare for shutdown (d)(1). Review this procedure and the four energy sources above. Tell the Bay 2 operators and lead that PB-03 is being locked out and why ((c)(9)).
- Shut down (d)(2). Finish or abort the cycle, lower the ram onto the safety blocks (E3), press STOP and turn the key switch to OFF.
- Isolate (d)(3). Open DS-3 (E1), close V-1 (E2) and AV-1 (E4).
- Apply locks and tags (d)(4). Each authorized employee fits a personal lock and tag to DS-3, V-1 and AV-1; group work uses the lock box described in the program.
- Control stored energy (d)(5). Open V-2 to bleed the accumulator to tank; dump the backgauge air; confirm the ram is resting on the blocks.
- Verify isolation (d)(6). Press START, each footswitch and each jog button: nothing may move. Test for zero voltage at the load side of DS-3 with a meter checked on a known live source. Check PG-1 and the air gauge read 0. Return all controls to OFF.
Release from lockout
- Remove tools and materials; check guards and tooling are back in place (e)(1).
- Make sure everyone is clear (e)(2)(i).
- Each employee removes their own lock and tag (e)(3); remove the safety blocks last before restart.
- Tell the operators the locks are off and the machine is about to restart (e)(2)(ii), (c)(9).
Annual inspection block
At the bottom of every procedure keep a certification block: date, inspector (an authorized employee who does not use this procedure), employees included, deviations found ((c)(6)). See the annual inspection guide.
Write yours in five minutes
The free generator lays out this same structure from your entries and prints it. The $49 kit adds the written program, inspection and training records, and a register that flags overdue inspections.
Another worked example: LOTO procedure for an inclined belt conveyor.
What makes a procedure "machine-specific"
Generic procedures that say "isolate all energy sources" are a common weakness. 1910.147(c)(4)(ii) asks for specific procedural steps for shutting down, isolating, blocking and securing the machine, for placing and removing devices, and specific requirements for testing that the measures work. In practice that means naming each isolating device and where it is, stating how each kind of stored energy is relieved, and saying exactly how you prove zero energy on this machine.
General information based on 29 CFR 1910.147 (eCFR.gov), not legal advice. The example machine is illustrative.