What is the Difference Between Lockout and Tagout?

In modern industrial environments, controlling hazardous energy is not optional - it is essential. Electrical, mechanical, hydraulic, pneumatic, thermal, and chemical energies can instantly become fatal when machines are serviced without proper isolation. We rely on lockout and tagout procedures to prevent accidental startup and unexpected energy release. While the terms are often used together, lockout and tagout are not the same. Each has a distinct function, legal implication, and safety outcome.

This comprehensive guide explains what islockout tagout, the difference between lockout and tagout, how each method works, and why correct implementation is critical for compliance, productivity, and worker survival.

Understanding Lockout and Tagout in Industrial Safety:

Lockout Tagout is a structured safety system used to isolate hazardous energy sources during equipment maintenance, repair, and inspection. It ensures machines cannot be energized while work is being performed. Lockout physically restrains energy flow, while tagout provides identification and warnings.

Together, they form a mandatory compliance requirement in many countries and are recognized as the most effective method to prevent serious injuries, amputations, electrocutions, and fatalities.

What Is Lockout?

Lockout is the physical isolation of an energy source using a locking device. A lock is applied to an energy-isolating device such as a circuit breaker, valve, switch, or plug. The equipment cannot be operated unless the lock is removed using a unique key.

Key Characteristics of Lockout:

●        Physically prevents machine activation

●        Uses padlocks, valve lockouts, breaker lockouts, plug lockouts, and hasps

●        Ensures total energy isolation

●        Provides the highest level of safety

●        Legally mandatory where feasible

Lockout is the primary and preferred safety control because it creates a hard-physical barrier between workers and hazardous energy.

What is Tagout?

Tagout is the placement of a warning tag on an energy-isolating device to indicate that the machine must not be operated. Safetytags communicate that maintenance is in progress and identifies the authorized worker responsible.

Key Characteristics of Tagout:

●        Does not physically block machine operation

●        Acts as a visual and procedural warning

●        Depends on human compliance

●        Used when lockout is not technically possible

●        Requires additional safety controls

Tagout is considered a secondary control and is only acceptable when lockout cannot be implemented due to equipment limitations.

Why Lockout is Safer than Tagout?

Lockout devices provide a mechanical barrier that eliminates the possibility of accidental machine activation. Even if someone tries to start the machine, the locked isolator physically prevents movement.

Tagout relies solely on procedural discipline. If someone ignores the warning, machinery can be started, leading to fatal incidents. This is why regulatory authorities mandate lockout whenever possible.

When is Tagout Allowed?

Tagout is only permitted when:

●        The equipment cannot accept a lock

●        The employer implements additional safety measures

●        The system provides equivalent protection

●        Workers receive specialized training

●        Continuous supervision is ensured

Even in these cases, employers must attempt to modify equipment to allow future lockout capability.

Common Lockout Devices Used in Industry:

Lockout devices physically secure energy sources, ensuring complete isolation and preventing accidental machine activation.

●        Safety Padlocks - Non-conductive, keyed-alike, and color-coded

●        Valve Lockouts - For gate, ball, butterfly, and globe valves

●        Circuit Breaker Lockouts - For MCB, MCCB, and toggle breakers

●        Plug Lockouts - For power cord isolation

●        Hasps - Allow multiple workers to apply personal locks

●        LOTO Stations - Centralized storage of lockout tools

Common Tagout Devices:

Tagout devices provide clear warnings. They communicate responsibility, maintenance status, and authorization, reinforcing procedural discipline and worker awareness.

●        Danger tags

●        Caution tags

●        Do Not Operate tags

●        Equipment identification tags

●        Maintenance in Progress tags

These are typically made of tear-resistant PVC and include space for name, department, date, and authorization.

Legal and Compliance Perspective:

Safety authorities globally recognize lockout as the primary compliance method. Tagout alone is considered insufficient unless additional safeguards are in place.

Non-compliance can result in:

●        Heavy fines

●        Legal prosecution

●        Business shutdown

●        Worker compensation claims

●        Fatal accidents and reputational loss

Benefits of Proper Lockout Tagout Implementation: