Free LOTO procedure template

What is a LOTO procedure template?

A lockout tagout (LOTO) procedure is a standard operating procedure that defines how energy sources are isolated and secured before maintenance or servicing work begins on plant and equipment. MapTrack helps operations teams manage LOTO procedures digitally so every isolation is recorded against the asset with full traceability. This overarching SOP is distinct from a per-job LOTO isolation checklist which is the field checklist completed for each specific isolation event. The procedure template defines the organisation-wide rules covering scope roles and responsibilities isolation types lock and tag requirements group isolation try-out verification and lock removal.

LOTO procedures are essential for preventing uncontrolled release of energy during maintenance. In Australia AS 4024.1603 (Control of hazardous energy - Lockout tagout and alternative methods) and the WHS Regulations set out requirements for isolation of plant. Failure to follow proper LOTO procedures is a leading cause of serious workplace injuries and fatalities in Australian industry. A well-documented LOTO procedure also addresses complex isolation scenarios such as multi-trade shutdowns where several work groups require simultaneous protection and long-duration isolations that span shift changes. The procedure should define how locks are transferred between shifts, how temporary de-isolation for testing is managed, and how the final re-energisation is authorised. Organisations that digitise their LOTO procedures can link each isolation event directly to the asset record, giving maintenance planners full visibility of isolation history, outstanding lock counts, and overdue removals.

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Benefits of digitising forms in MapTrack

When you move your procedures from paper to MapTrack, you get:

• Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
• Automatically get alerts when faults are identified.
• Link every form digitally as a PDF to the relevant asset, location or person.
• Receive a digital PDF copy with every submission to your email.
• Ability to share forms digitally.
• Build conditional logic (show or hide questions based on answers).
• Take pictures or attach photos. Not possible with a paper-based form.
• Electronic signatures.
• Edit forms later without reprinting.
• Restrict permissions (who can view, complete or approve).
• Build forms with AI (describe what you need and MapTrack suggests the form).
• Escalate critical hazards instantly to safety managers via push notification.
• Maintain an auditable safety register that satisfies WHS regulator requests.
• Correlate incident trends across sites with built-in safety analytics.

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What to include in a LOTO procedure template

This LOTO procedure template covers 8 key areas:

• Scope and purpose: define which plant equipment and energy types the procedure covers and state its purpose in preventing uncontrolled energy release
• Roles and responsibilities: define the roles of the authorised person (who authorises isolation) the competent person (who performs isolation) and the affected person (who works on the isolated plant)
• Energy types: list all energy types covered including electrical hydraulic pneumatic mechanical gravitational thermal and chemical
• Lock and tag requirements: specify the types of locks and tags to be used personal lock requirements and the rule that each worker applies their own lock
• Isolation steps: describe the step-by-step process for isolating each energy type including shutdown sequence isolation point identification and lock application
• Try-out and verification: define the process for verifying zero energy after isolation is applied including try-start and testing with appropriate instruments
• Group isolation: describe the procedure for multi-person lockout including the use of a group lockout box or hasp and the requirement for each worker to apply their personal lock
• Lock removal and re-energisation: define the process for removing locks restoring energy and confirming the plant is safe to return to service

How often should you complete this procedure?

The LOTO procedure should be reviewed at least annually as part of the organisation's safety management system review cycle. It should also be reviewed immediately after any incident or near miss involving an isolation failure after the introduction of new plant or equipment and whenever there is a change in legislation or standards.

AS 4024.1603 requires that procedures for the control of hazardous energy are documented maintained and reviewed. The WHS Regulations require the PCBU to ensure that risks associated with plant are managed and that isolation procedures are followed. Regular review ensures the LOTO procedure remains current and effective as the workplace evolves.

Applicable regulatory standards

This template aligns with the following regulations and standards:

• AS/NZS 4024.1603 - Control of hazardous energy (Lockout/tagout)
• WHS Regulations - Chapter 5 Plant and structures
• OSHA 29 CFR 1910.147 - Control of hazardous energy

Related resources

More safety templates and guides:

• Loto Isolation Checklist
• Confined Space Entry Permit
• Hot Work Permit
• Electrical isolation checklist
• Tag out service notice
• Compliance
• All templates
• Resource centre