Lockout Tagout Annual Audit
This standard operating procedure details the process for performing the mandatory annual audit of your facility's lockout/tagout (LOTO) program as required by CSA Z460 and WorkSafeBC regulations. The audit verifies that every energy-isolating device, written procedure, and operator training remains effective and up to date.
The annual lockout tagout audit ensures that all written machine-specific procedures accurately reflect current energy isolation points, that every lockout device functions correctly, and that each authorized and affected employee has received documented training within the past year. Detecting gaps in the LOTO program before an accident occurs is the primary objective.
This procedure applies to all production machinery, packaging lines, conveyors, robotics, and any other equipment with stored energy (electrical, mechanical, pneumatic, hydraulic, thermal, or chemical) at the facility. It covers the physical inspection of lockout hardware, verification of zero-energy states, review of machine-specific procedures, and assessment of employee competency. The audit must be completed by a qualified safety officer or a team comprising the plant manager, maintenance lead, and a joint health and safety committee member.
- Never bypass or disable any existing lockout device during the audit. If a device appears faulty, do not remove it – escalate to the maintenance supervisor immediately.
- Auditors must wear CSA‑approved safety glasses, steel‑toed boots, and high‑visibility vest at all times in the production area. Non‑conductive gloves required when handling electrical isolation points.
- When performing zero‑energy verification, always use a properly rated voltage tester and confirm it works on a known live source immediately before and after testing.
- No lockout devices may be removed or tampered with except by the authorized employee who installed them. For group lockout, follow the shift‑crew procedure precisely.
- Auditors must coordinate with the control room/supervisor before isolating any equipment. All affected employees must be notified that an audit is in progress and to stay clear of machines under test.
- Master LOTO logbook (digital or paper) – latest version
- Machine‑specific LOTO procedure binders for every piece of equipment
- Sample of 10% of all lockout padlocks, hasps, tags, and group boxes (minimum 10 samples)
- Non‑contact voltage tester / multimeter (rated for the highest voltage on site)
- Pressure gauge and quick‑connect fittings for pneumatic/hydraulic verification
- Training attendance records and sign‑off sheets for all authorized & affected employees
- Audit checklist template (download from Ryxen SOP Library)
- Digital camera or mobile device for photographic evidence of deviations
- LOTO cabinet key log and key inventory sheets
- Personal protective equipment (as listed in safety precautions above)