This Lockout Tagout Application & Removal SOP (Safe Operating Procedure) sets out the general method for isolating plant and equipment before maintenance, repair, cleaning, adjustment, clearing blockages or inspection. It covers identifying every energy source, isolating and dissipating stored energy, blocking parts against gravity, personal locks and tags, group lockout, try-out testing, and safe removal and re-energising. It's written by WHS specialists, aligned to Australian WHS legislation, and fully editable in Microsoft Word.
Who it's for
Manufacturers and factories
Maintenance and engineering teams
Food and beverage processors
Mining, quarrying and agricultural businesses
Electrical and mechanical contractors
Use it to
Train and induct workers in exactly how you expect the task to be done
Keep a clear reference at the machine, in the vehicle or on site
Record competency with the built-in sign-off
Show clients, insurers and auditors your safe work methods are written down
What this SOP covers
Electric shock from live circuits or conductors
Crush, entanglement or amputation from unexpected start-up
Sudden release of stored hydraulic or pneumatic pressure
Raised or suspended parts dropping when support is released
Burns from hot surfaces, steam or residual heat
Plant re-energised while a worker is still exposed
Missed or wrongly sequenced energy sources
Faulty isolation devices, bypassed safety devices or locks on the wrong point
What's included
6 pre-operational checks, from training and personal padlocks to energy sources, lockout hasps, group lockout boxes and affected workers
A 19-step operating procedure covering identifying energy sources, isolating, dissipating stored energy, personal locks, try-out testing and safe removal
Isolation and energy control for electrical, hydraulic, pneumatic, mechanical stored energy and gravity
5 shutdown, housekeeping and post-operation steps
Emergency actions for unexpected start-up, tampered locks or tags and injuries from energisation
PPE checklist and a list of related documents
Competency acknowledgement and worker sign-off
Space for your logo, SOP number, version and review dates
Why use this template
Saves hours compared with writing an SOP from a blank page
Written as clear, numbered steps that workers can follow on the job
Fully editable, so you can match it to your equipment, site and how your team works
The competency sign-off gives you a training record from day one
How it works
Buy online and download straight away. You'll also get an email with your link.
Add your logo, company name, SOP number and dates.
Check it suits your equipment and site, and edit anything you need to.
Train your workers and have them sign the competency acknowledgement.
Need more than one SOP?
This SOP is also included in the Ultimate Manufacturing & Industrial SOP Bundle. At $197 for the whole bundle, it works out much cheaper than buying SOPs one at a time.
Common questions
Does it cover group lockout?
Yes. Where more than one person is exposed, each fits their own padlock to a lockout hasp or locks a group lockout box holding the isolation keys.
Who can remove a lock or tag?
Only the person who applied it. If they're unavailable, your documented alternative-removal process is followed, confirming isolation is no longer needed and the person is accounted for.
Does it include isolation points for specific machines?
No. It's a general procedure. Specific isolation points for a particular machine are set out in plant-specific procedures where they exist.
Can I change it?
Yes. It's a Microsoft Word file, so you can add, remove or change any step, check or hazard, and add your own logo and details.
Does it suit my state?
Yes. It's written to the model WHS laws and suits all states and territories, including Victoria under the OHS Act and Regulations.
What if it doesn't suit my work?
You're covered by our 30-day money-back guarantee if it isn't fit for purpose.
