OSHA’s #4 Most Cited Violation of 2025: Lockout/Tagout (1910.147)
Lockout/Tagout violations rank #4 on OSHA’s Top 10 list for 2025, with 2,177 citations for missing programs, training, and verification steps. Learn why energy-control failures continue to plague industries and how Advanced Safety & Industrial Supply can help you build a fully compliant LOTO program to protect your workers and avoid costly fines.
Why Energy-Control Failures Still Rank High — and How to Prevent Them
When it comes to preventing catastrophic injuries, few programs are as essential—or as frequently violated—as Lockout/Tagout (LOTO). In FY 2025, OSHA recorded 2,177 citations under 1910.147, ranking it #4 on the list with 266 fewer violations than last year.
Even with improved awareness, too many facilities still rely on outdated procedures, missing documentation, or inconsistent employee training. One mistake can lead to serious injury or death.
Why Lockout/Tagout Keeps Appearing in OSHA’s Top 10
1. No Written LOTO Program
Many companies have procedures—but not a compliant written plan. OSHA requires a document that lists:
-
Each piece of equipment covered
-
Energy-control steps
-
Authorized employees
-
Verification process
Without a formal, equipment-specific procedure, it’s a guaranteed citation.
2. Failure to Train or Retrain Workers
OSHA mandates three types of training:
-
Authorized employees (who perform lockout)
-
Affected employees (who work nearby)
-
Other employees (who must recognize locks/tags)
Training must be documented and refreshed whenever new equipment or processes are introduced.
3. Missing or Inadequate Devices
Citations often arise when:
-
Locks are missing or shared
-
Tags aren’t durable or legible
-
Devices don’t fit the energy source
-
Locks are removed without proper sign-off
Each employee performing lockout must have their own unique lock and key.
4. Failure to Verify Isolation
LOTO isn’t complete until energy is verified as zero. OSHA frequently cites companies for skipping this “try-out” step before servicing equipment.
5. Contractors Not Included
Outside service crews must follow the host employer’s LOTO program—or you must integrate theirs. Coordination failures often trigger citations.
How to Stay Compliant With 1910.147 in 2025
✔ Develop and Maintain Written Procedures
List each piece of machinery, energy sources, and isolation methods. Review annually.
✔ Provide Documented Training
Keep written records by employee and renewal date.
✔ Use Durable, Standardized Devices
Color-code locks by department, engrave employee names, and never share keys.
✔ Verify Energy Isolation
Require proof of zero-energy state before maintenance begins.
✔ Audit Annually
A “periodic inspection” must be conducted every 12 months and documented by a qualified employee.
How Advanced Safety & Industrial Supply Helps
At Advanced Safety & Industrial Supply, we help manufacturers and maintenance teams close compliance gaps with:
✅ Written LOTO program development
✅ Facility energy-source mapping
✅ Authorized employee training
✅ Periodic inspection templates
✅ Lockout device kits and signage
✅ On-site audits and mock OSHA inspections
Let our team help your facility reduce citations, prevent accidents, and protect your workforce.
Call (615) 739-3278 or Contact Us now to schedule training or an onsite evaluation.
Why Energy-Control Failures Still Rank High — and How to Prevent Them
When it comes to preventing catastrophic injuries, few programs are as essential—or as frequently violated—as Lockout/Tagout (LOTO). In FY 2025, OSHA recorded 2,177 citations under 1910.147, ranking it #4 on the list with 266 fewer violations than last year.
Even with improved awareness, too many facilities still rely on outdated procedures, missing documentation, or inconsistent employee training. One mistake can lead to serious injury or death.
Why Lockout/Tagout Keeps Appearing in OSHA’s Top 10
1. No Written LOTO Program
Many companies have procedures—but not a compliant written plan. OSHA requires a document that lists:
-
Each piece of equipment covered
-
Energy-control steps
-
Authorized employees
-
Verification process
Without a formal, equipment-specific procedure, it’s a guaranteed citation.
2. Failure to Train or Retrain Workers
OSHA mandates three types of training:
-
Authorized employees (who perform lockout)
-
Affected employees (who work nearby)
-
Other employees (who must recognize locks/tags)
Training must be documented and refreshed whenever new equipment or processes are introduced.
3. Missing or Inadequate Devices
Citations often arise when:
-
Locks are missing or shared
-
Tags aren’t durable or legible
-
Devices don’t fit the energy source
-
Locks are removed without proper sign-off
Each employee performing lockout must have their own unique lock and key.
4. Failure to Verify Isolation
LOTO isn’t complete until energy is verified as zero. OSHA frequently cites companies for skipping this “try-out” step before servicing equipment.
5. Contractors Not Included
Outside service crews must follow the host employer’s LOTO program—or you must integrate theirs. Coordination failures often trigger citations.
How to Stay Compliant With 1910.147 in 2025
✔ Develop and Maintain Written Procedures
List each piece of machinery, energy sources, and isolation methods. Review annually.
✔ Provide Documented Training
Keep written records by employee and renewal date.
✔ Use Durable, Standardized Devices
Color-code locks by department, engrave employee names, and never share keys.
✔ Verify Energy Isolation
Require proof of zero-energy state before maintenance begins.
✔ Audit Annually
A “periodic inspection” must be conducted every 12 months and documented by a qualified employee.
How Advanced Safety & Industrial Supply Helps
At Advanced Safety & Industrial Supply, we help manufacturers and maintenance teams close compliance gaps with:
✅ Written LOTO program development
✅ Facility energy-source mapping
✅ Authorized employee training
✅ Periodic inspection templates
✅ Lockout device kits and signage
✅ On-site audits and mock OSHA inspections
