Many organizations understand the importance of Lockout Tagout safety, but there are still many who struggle to implement it correctly. The intention behind implementation of lockout tagout procedure is always to protect workers from hazardous energy sources. But even a small lapse in execution can lead to major risks. At Globalite Safety Solutions Private Limited, we are working with multiple industries and are observing a few recurring mistakes they make causing problem in the overall safety program.
Addressing these mistakes is the first step towards creating a stronger and more responsible working environment for every employee. In this blog, we are sharing a few common mistakes and ways to avoid them for maintaining proper safety.
Inadequate identification of energy sources
One of the most frequent issues occurs even before the lockout procedure begins. Machines often have multiple energy sources that are not easy to identify or document. When teams assume a machine has only a single source of power, they often miss hidden hazards. Such hazards are available in the form of pneumatic, hydraulic, and mechanical energy. This creates a false sense of safety and puts workers at risk when maintenance starts. A thorough survey, clear labelling and routine review of equipment ensure that teams always lock out every relevant source without leaving anything unchecked.
Improper or inconsistent use of lockout devices
We also notice that many facilities rely on makeshift methods or inconsistent use of approved devices during critical tasks. Using a shared lock, not assigning personal locks or skipping tags because of perceived time pressure weakens the entire Lockout Tagout program. When locks are not individually assigned, it becomes difficult to confirm who is responsible for a specific machine. Safety improves significantly when every authorized employee has dedicated locks, clear tags and the confidence that no one can restore power until their task is completed. Consistency in device usage creates trust and eliminates confusion during maintenance or shift changes.
Lack of proper training and periodic refreshers
Even the most well designed safety procedures fail, when working with untrained professionals. Many companies conduct a single training session once a year and assume employees will remember every step. Over time, people forget smaller details that play a crucial role in Lockout Tagout Safety. Also, new workers join, procedures change, and new machines and technology come into picture, leading to increase in the need for ongoing learning. When conducting training sessions, we focus on real scenarios and practical understanding to make teams perform every step naturally without hesitation. Regular reminders ensure that employees remain alert, updated and fully aware of their responsibilities.
Conclusion
Avoiding these common mistakes not only strengthens compliance but also creates a safer and more efficient workplace. We believe that Lockout Tagout Safety is one such rule that one must follow with discipline, clarity and teamwork. With proper identification, consistent device usage, ongoing training and zero energy verification, companies can reduce risks and protect their workforce. At Globalite Safety Solutions Private Limited, we are dedicated to help organizations build dependable safety practices that support both productivity and employee wellbeing.
