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Forklift Lock Out Tag Out Procedures

Lockout refers to the practice of using keyed or combination locks to prevent the use of equipment that needs repair or is receiving routine maintenance. The use of non-reusable tags can be used in conjunction with the locks to increase visibility and awareness that the equipment is not to be used until repair or maintenance has been completed. This is called tagout. Compliance with lockout-tagout procedures prevents an estimated 120 deaths and 50,000 injuries annually.

  1. Lockout Procedure

    • The first phase of lockout is notifying all affected employees that service or maintenance is required on the forklift. Also, inform the employees that the forklift must be shut down and locked out. An authorized employee must determine if the forklift is operating. If so, it must be shut down normally. Next, the authorized employee must deactivate any energy activating devices on the forklift so that it cannot be turned on. Examples of energy activating devices are blinds, circuit breakers, valves, and electrical disconnects. Place keyed or combination locks on the energy activating devices. After the deactivation of energy, the forklift must be tested to ensure it cannot be started or operated. Before testing, the authorized employee must make sure that no personnel are exposed to the forklift. When testing is complete, return all power switches on the forklift to the off position. The forklift is now locked out.

    Tagout Procedure

    • Along with locking out the forklift, authorized employees may also tag out equipment for increased visibility that the equipment is not to be used. This is done by placing a universal "Danger" tag on any energy-activating devices. Before placing the tag on the forklift, the authorized employee should write why the forklift is inoperable on the tag and sign it. It is important to note that when repair or maintenance is required by more than one individual, each person involved with repair and maintenance should apply their own lock and personal tag. The forklift should not be operated until each authorized individual removes his or her lock and tag.

    Return Procedure

    • After the repairs are completed and verified by an authorized employee, all other employees should be notified that the forklift has been serviced and is available for use. Ensure that all tools and materials have been removed from the area. Also, make sure that employees will not be exposed to any hazard when restarting the forklift. After all employees have been notified, the locks and or tags may be removed and the forklift may be operated.

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