Essential Lock-Out/Tag-Out Practices for Agricultural Safety

Agricultural machinery powers much of the work on farms, but it also poses serious risks during maintenance. Accidental startup or release of stored energy in equipment can cause severe injuries or even fatalities. Lock-out/tag-out (LOTO) procedures provide a clear, effective way to protect workers by ensuring machines stay off while being serviced. This post explains what LOTO means, why it matters in agriculture, and how to apply it correctly to keep everyone safe.

Lock-out/tag-out applied on a power switch

What Lock-Out/Tag-Out Means

Lock-out/tag-out is a safety process that involves shutting down equipment and isolating it from energy sources to prevent accidental operation. The process uses physical locks and warning tags placed on power switches, valves, or controls. These devices block the equipment from being turned on and clearly communicate that maintenance is underway.

In practice, lock-out means physically locking the control point so it cannot be activated. Tag-out means attaching a visible tag that warns others not to operate the equipment. Together, they create a strong barrier against accidental startup.

Why Lock-Out/Tag-Out Is Critical in Agriculture

Agricultural workers often maintain machines like tractors, combines, conveyors, and irrigation pumps. These machines contain powerful motors, hydraulic systems, and stored energy that can cause crushing, cutting, or entanglement injuries if they start unexpectedly.

For example, a worker repairing a conveyor belt could be seriously hurt if the belt suddenly moves. Similarly, hydraulic pressure in farm equipment can release energy even after the machine is turned off. LOTO procedures ensure that all energy sources are isolated and controlled before work begins.

Statistics from the U.S. Occupational Safety and Health Administration (OSHA) show that thousands of agricultural workers suffer injuries each year due to equipment accidents. Implementing LOTO reduces these risks by creating a clear, enforceable safety protocol.

Basic Steps to Follow for Lock-Out/Tag-Out

Applying LOTO correctly requires following a series of clear steps:

• Notify affected workers

Inform everyone who might be impacted that equipment will be shut down for maintenance.

• Turn off and isolate equipment

Shut down the machine and disconnect it from all energy sources such as electrical power, fuel, or hydraulics.

• Apply lock and tag

Place a lock on the power switch or energy isolation device. Attach a tag that clearly states the equipment is out of service and who applied the lock.

• Release or block stored energy

Drain hydraulic or pneumatic pressure, release springs, or block moving parts to prevent unexpected motion.

• Verify de-energization

Test the equipment controls to confirm the machine cannot start or move.

• Perform maintenance safely

Only after verification can workers begin repairs or servicing.

• Remove lock and tag after work

Once maintenance is complete, remove the lock and tag, notify affected workers, and restore power.

Following these steps consistently prevents accidents and protects workers from injury.

Tips for Effective Lock-Out/Tag-Out in Agriculture

To make LOTO work well on farms, consider these practical tips:

• Train all workers

Everyone involved in equipment maintenance should understand LOTO procedures and why they matter. Regular training refreshes knowledge and builds safety habits.

• Use durable locks and tags

Choose locks that cannot be easily removed and tags that are weather-resistant and clearly visible.

• Update policies regularly

As new machinery or energy sources are introduced, review and revise LOTO procedures to cover all risks.

• Encourage a safety culture

Promote responsibility among all workers to follow LOTO rules and speak up if they see unsafe practices.

• Keep clear documentation

Maintain records of LOTO applications and training sessions to track compliance and identify areas for improvement.

Real-World Example of LOTO in Agriculture

Consider a farm where workers maintain an irrigation pump powered by an electric motor and hydraulic valves. Before servicing, the worker:

1. Notifies the team that the pump will be shut down.

2. Switches off the electric motor and disconnects the power supply.

3. Applies a lock and tag on the main power switch.

4. Releases hydraulic pressure by opening valves and blocking moving parts.

5. Tests the pump controls to confirm it cannot start.

6. Performs the maintenance work safely.

7. Removes the lock and tag after finishing and informs the team.

   
   

This process prevents accidental startup, protecting the worker from electrical shock, hydraulic pressure release, or mechanical injury.

Building Safety Into Every Maintenance Task

Lock-out/tag-out is not just a procedure but a mindset. Every time maintenance is planned, workers should pause and apply LOTO steps without exception. This habit reduces injuries and builds trust among teams.

Farm managers can support this by providing proper equipment, clear instructions, and ongoing training. Workers should feel empowered to stop work if they notice missing or improper LOTO measures.

By making LOTO a routine part of agricultural maintenance, farms can create safer workplaces and reduce costly accidents.

JML Safety Consulting: Your Leading Provider for LOTO Training

Understanding LOTO Training

Lockout/Tagout (LOTO) training is essential for ensuring employee safety around hazardous machinery. It educates personnel on the correct lock and tag procedures to prevent accidental energization during maintenance activities.

Advantages of LOTO Training

• Enhances safety and reduces the risk of accidents.

• Improves compliance with regulatory standards.

• Boosts employee confidence and competence.

• Fosters a culture of safety within the organization.

Initiate Your Training Today!

Secure workplace safety with JML Safety Consulting's LOTO training. Contact us to schedule a consultation or to learn more!