Lockout Tagout SWMS

Lockout tagout is the single most important safety procedure in manufacturing. Failure to properly isolate energy sources before maintenance, cleaning, and changeover work is the leading cause of machine-related fatalities and amputations in Australian manufacturing. The WHS Regulation 2025 requires PCBUs to ensure that plant is isolated from all energy sources and that isolation is verified before any person enters a danger zone. Energy sources include electrical, pneumatic, hydraulic, gravitational, mechanical stored energy, thermal, and chemical energy. This template maps controls to the binding Managing Risks of Plant Code of Practice effective 1 July 2026 under Section 26A.

Legal Requirements

regulation

WHS Regulation 2025 Part 4.7 — Plant

hrcw category

Plant isolation and maintenance

code of practice

Managing Risks of Plant in the Workplace (binding 1 July 2026 under Section 26A)

section 26a binding

Yes — effective 1 July 2026. Non-compliance is admissible as evidence of breach.

Hazards

Hazard	Consequence	Likelihood
Unexpected machine start-up during maintenance or cleaning	Amputation, crush injuries, death	Possible
Stored energy release from pneumatic, hydraulic, or spring systems	Projectile injuries, crush, lacerations	Possible
Electrical contact during work on energised equipment	Electrocution, arc flash burns, cardiac arrest	Unlikely
Gravitational energy release from raised components or loads	Crush injuries, death	Possible
Thermal energy exposure from hot surfaces or residual heat	Burns, scalds	Likely
Chemical energy from residual contents in pipes and vessels	Chemical burns, toxic exposure	Possible

Controls (Hierarchy of Controls)

Develop machine-specific LOTO procedures identifying every energy source and isolation point for each machine

Provide personal padlocks and tags for every worker who performs LOTO — locks must be unique and non-duplicated

Implement a multi-lock hasp system for machines requiring isolation by multiple workers simultaneously

Verify zero energy state after lockout by attempting to start the machine and testing for residual energy

Establish a permit system for complex isolations involving multiple energy sources or shared systems

Train all maintenance, cleaning, and production workers in LOTO procedures with practical assessment

Conduct annual LOTO procedure audits comparing documented procedures to actual isolation points

Display machine-specific LOTO procedures at each isolation point with diagrams showing all energy sources

Recent Prosecutions

SafeWork SA prosecution$840,000

Apprentice killed during maintenance on manufacturing equipment where lockout tagout procedures were not followed and supervision was inadequate.

2024 — SafeWork SA Manufacturing Prosecution [2024]

Orica Australia Pty Ltd$1,200,000

Multiple safety failures including inadequate isolation and maintenance procedures in industrial operations.

2024 — SafeWork NSW v Orica Australia Pty Ltd [2024]

What Your SWMS Must Include

✓Machine-specific LOTO procedures for every machine requiring isolation

✓Energy source identification covering electrical, pneumatic, hydraulic, gravitational, thermal, and chemical

✓Personal lock and tag allocation register

✓Zero energy verification procedure for each machine

✓LOTO training program with practical competency assessment

Need a compliant Lockout Tagout SWMS?

Our WHS consultants build machine-specific LOTO procedures that identify every energy source and protect your workers during maintenance, cleaning, and changeover.