Lockout Safety Pros conduct gap assessments of your current procedures, locks, and signage to ensure OSHA compliance, including effective equipment labeling for LOTO compliance.
We provide machine-specific LOTO procedures that are tailored to your equipment and processes, ensuring proper equipment labeling and compliance with LOTO standards through thorough gap assessments.
Our professional-grade labels and device marking ensure compliance with LOTO regulations and aid in effective equipment labeling, thus preventing confusion during gap assessments.
Whether you're managing a single machine or an integrated manufacturing line, Lockout Safety Pros provides comprehensive Lockout/Tagout (LOTO) reviews and gap assessments to help you achieve LOTO compliance with OSHA 1910.147 and ANSI Z244.1 requirements — utilizing real-world, field-tested solutions that work effectively.
Remote or On-Site: Your Choice
We offer both remote reviews and in-person audits, depending on your facility's needs and location. Whether you're looking to evaluate:
A single standalone machine
A multi-point CNC or machining center
An integrated production line with dozens of lockout points
Or even complex processes such as:
Chemical process systems
Thermoforming & heating ovens
Gas & pneumatic LOTO
Hydraulic press lines
Combination energy systems (mechanical + stored electrical + pneumatic)
— our team brings the tools and experience to accurately assess risk, identify compliance gaps, and ensure proper equipment labeling.
What Our Gap Assessment Covers
Our LOTO Gap Assessment goes far beyond just checking boxes. We:
Compare your existing LOTO procedures against current OSHA & ANSI standards.
Identify missing or inadequate lockout points — such as unlabeled disconnects, shared energy sources, or equipment still energized during “locked out” states.
Detect areas where stored energy is not fully dissipated (e.g., trapped hydraulic pressure or gravity-loaded mechanical motion). Assess visual lockout cues like tags, placards, energy source IDs, and warning labels. Review the applicability of group lockout and isolation hierarchy for complex assets.
Deliverables You Can Act On
At the conclusion of your review, you’ll receive a detailed report that includes:
A compliance score per asset or process
Annotated pictures of lockout points and deficiencies
Clear, prioritized recommendations for corrective action
Guidance for bringing your current procedures into full compliance.
Notes on residual risks (e.g., latent motion, static charge, stored heat) that may remain even during a valid lockout.
All findings are tied to the relevant standards, including:
OSHA 1910.147
ANSI/ASSE Z244.1
NFPA 70E (for electrical energy hazard context)
ANSI B11.0 / B11.19 (if applicable to machine-specific LOTO controls)
Off-the-shelf templates don’t keep workers safe — and they won’t pass an OSHA audit. At Lockout Safety Pros, we create machine-specific, OSHA 1910.147-compliant Lockout/Tagout (LOTO) procedures tailored to your actual equipment, energy types, and site conditions. Our focus on proper equipment labeling ensures that every procedure is clear and effective.
Whether you need one or 100 procedures, we deliver clear, compliant, and field-ready documentation that works for your operators and satisfies any auditor, including during gap assessments.
What We Include in Every Procedure
Each procedure is:
✅ Written specifically for your machine (not copy-pasted)
✅ Includes all energy sources: electrical, pneumatic, hydraulic, thermal, chemical, gas, gravity, or mechanical
✅ Clearly identifies primary and secondary isolation points
✅ Labeled and matched to field-installed equipment tags
✅ Includes photos and diagrams of each lockout step and location
✅ Aligned with your facility’s lockout devices (breaker lockouts, plug lockouts, valve covers, etc.)
✅ Compatible with group lockout/tagout setups where applicable
✅ Designed for authorized employee use — readable, practical, and actionable
What Types of Equipment Do We Cover?
We’ve developed procedures for:
CNCs, machining centers, and robotics
Conveyors, palletizers, and material handling systems
Mixers, extruders, and ovens (thermal and gas-powered)
Hydraulic presses and forming equipment
Complex integrated lines with multiple control panels and energy zones
Thermoforming, packaging, and chemical process systems
No machine is too simple or too complex — our process ensures every isolation point is accounted for.
What You Receive
A professionally formatted PDF procedure for each machine
Photo-based visual guidance (can include your equipment labels and tags)
An editable version (Word or Excel) if your team needs to make future updates
Optional: Matching machine labels and placards to tie it all together
Proper equipment labeling is not merely a housekeeping task; it plays a crucial role in ensuring LOTO compliance and maintaining a functional Lockout/Tagout program. At Lockout Safety Pros, we exceed basic stickering by conducting comprehensive gap assessments and a full verification and validation of your equipment’s labeling against your schematics, controls, and energy isolation strategy.
Whether you’re preparing for an OSHA inspection or cleaning up post-install chaos, we help elevate your labeling system to meet standards and ensure it remains maintainable in the future.
What We Do
We perform a meticulous field-to-drawing verification of all safety and process devices, including:
✅ Input Devices:
E-stops, gate switches, light curtains, interlock switches, presence sensors
✅ Output Devices:
Solenoids, valves, relays, cylinders, actuators
✅ Process Devices:
Flow sensors, temperature switches, pressure switches, vacuum sensors
✅ Safety System Components:
Safety relays, safety PLC I/O, guard-locking solenoids, enabling switches
For each device, we verify:
- Proper installation and function
- Physical label is present and legible
- Label matches the schematic device tag (e.g., CR6.1, LS2, M2.2)
- Cross-referenced with electrical, pneumatic, and hydraulic drawings
Optional Deliverable: 3D Machine Mockup
For facilities requiring enhanced documentation, we offer a 3D layout or annotated machine diagram that displays:
- Every labeled component by location
- Tags and device numbers corresponding to your schematics
- Grouped by system: electrical, pneumatic, hydraulic, and mechanical
Ideal for training, troubleshooting, and safety validation.
Why It Matters
- Avoid confusion during lockout or emergency response
- Support accurate procedure development
- Assist maintenance and electricians with fast diagnosis
- Comply with ANSI Z535.4 and OSHA 1910.147(e)(1) for energy control identification
- Align with best practices in machine safety (ANSI B11.19 / B11.26)
What You Get
- Fully verified labeling matrix (device name, location, tag, drawing reference)
- On-machine label installation (if included in scope)
- Optional 3D visualization of labeled systems
- Documentation bundle suitable for audits, onboarding, and engineering reference
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