Standard solution: safe disconnection and locking before work (LOTO)
Make the machine de-energized before putting your hand in
Most serious workshop accidents occur because a machine started unexpectedly, a part moved, or stored energy was released while someone had their hands inside it. The principle of making the machine de-energized and securing it against restart — called Lockout/Tagout (LOTO) — prevents precisely this.
§1. Identify energy sources
- 01Mechanical: raised tools, springs and parts that can fall or jump.
- 02Hydraulic and pneumatic: pressure in cylinders, accumulators and hoses.
- 03Electrical: battery, generator and control units.
- 04Thermal: hot engine, exhaust, and coolant.
§2. Stands and remove power
- 01Lower equipment and load to the ground or mechanically support them.
- 02Stop the engine and take the ignition key.
- 03Relieve hydraulic and air pressure according to the manufacturer's instructions, including in accumulators.
- 04Disconnect the battery main switch/negative terminal where relevant.
- 05Let hot parts cool off before working on them.
§3. Secure against restart
- 01Put a lock/block on the main switch where the machine allows it.
- 02Put a clear sign on the control: "Work in progress — do not start".
- 03Tell colleagues that the machine is out of service and why.
- 04Keep control of the key and lock yourself until the work is finished.
§4. Verify and finish
- 01Confirm that the machine cannot start or move before you begin.
- 02First remove security mark and lock when all are out of the hazard area.
- 03Reinstall guards and safety equipment before starting.
- 04Test run controlled and confirm everything works.