How to Use Lock Out Tags with Pictures: A Step-by-Step Guide for Workplace Safety

16 min read•For Thesafetyfactory.com

Lockout/tagout procedures are among the most critical safety protocols in any facility. When energy sources are not properly controlled during maintenance or servicing, workers face serious risk of injury from unexpected equipment startup or the sudden release of stored energy. Lock out tags with pictures take standard LOTO compliance a step further, combining written warnings with visual symbols that communicate danger instantly, regardless of a worker's language or literacy level.

For facility managers and maintenance professionals, picture-based tags are a practical tool for meeting OSHA's Control of Hazardous Energy standard (29 CFR 1910.147) while making safety information accessible to every person on the floor. Standardized pictograms based on ANSI Z535 and ISO 3864 guidelines are widely recognized in the safety industry as effective for crossing language barriers, making them especially valuable in diverse workplaces.

This guide walks you through the complete process: understanding what picture-based lock out tags are, selecting the right tags for your equipment, building machine-specific LOTO procedures, training your team, applying and removing tags correctly, and maintaining compliance through regular audits. Whether you are building a lockout/tagout program from scratch or upgrading an existing one, these steps will help you implement picture-based lock out tags effectively across your facility.

Step 1: Understand What Lock Out Tags with Pictures Are and When to Use Them

Picture-based lock out tags are safety tags that combine color-coded signal words, standardized hazard pictograms, and written warnings to communicate danger clearly at the point of energy isolation. The pictograms typically follow ANSI Z535 or ISO 3864 standards, which means the symbols carry consistent meaning across facilities and industries. Common examples include the electrical bolt symbol for electrical hazards, valve and pipe symbols for pneumatic or hydraulic systems, and flame or temperature symbols for thermal hazards.

Before using these tags, it is important to understand a fundamental distinction under OSHA 1910.147: a lockout tag is not the same as a lockout device, and the two are not interchangeable in most situations.

Lockout devices physically prevent energy-isolating equipment from being operated. Examples include hasps, lockout blocks, and valve covers secured with a padlock. These provide a positive, physical means of isolation.

Lockout tags are warning devices attached to energy-isolating points to communicate that the equipment must not be operated. Under OSHA 1910.147, tags may only be used without a lockout device when the energy-isolating device is not capable of being locked out. If a lockout device can be applied, it must be used. Using a tag alone when a device could have been applied is a compliance violation.

Picture-based lock out tags are appropriate across a wide range of equipment and systems, including electrical panels and disconnects, machinery with mechanical energy sources, pneumatic and hydraulic systems, thermal systems, chemical lines, and any equipment with gravitational energy such as suspended parts or counterweights.

Only trained, authorized employees may apply or remove lockout/tagout devices. Affected employees, those who work in the area but do not perform the servicing, must understand what the tags mean but are not permitted to remove them.

Picture-based tags are especially valuable in multi-language workplaces where text-only tags may not communicate effectively to every worker. A symbol-based warning can convey "do not operate" or "electrical hazard" to a worker who reads a different language, or to someone who simply processes visual information faster under pressure. Learn more about how operational hazard tags prevent danger in real-world facility environments.

One common pitfall to avoid: never use a tag as a substitute for a lockout device simply because it is faster or more convenient. If the isolation point can accept a lock, a lock must be used alongside the tag.

Step 2: Select the Right Lock Out Tags for Your Equipment and Hazards

Not all lock out tags are created equal, and selecting the right tag for each energy source in your facility is a critical step in building an effective LOTO program. Start by conducting a thorough inventory of the energy types present in your facility.

Common energy sources to account for include electrical, hydraulic, pneumatic, thermal, chemical, and gravitational energy. Each type carries distinct hazards, and picture-based tags should reflect those specific dangers through appropriate pictograms and signal words.

Match the pictogram to the hazard. An electrical panel should carry a tag featuring the electrical bolt symbol and a DANGER signal word. A pneumatic valve should carry a tag with an air pressure or pipe symbol. A high-temperature system should display a heat or flame pictogram. Using the correct symbol ensures that anyone approaching the equipment immediately understands the nature of the hazard, not just the fact that one exists.

Evaluate material durability. OSHA 1910.147 requires that tags be constructed to withstand the environmental conditions where they are used. In facilities with exposure to heat, moisture, chemicals, or UV light, standard paper tags will degrade quickly. Look for weatherproof laminated safety tags that maintain legibility throughout the duration of the lockout. A tag that fades or tears is not compliant.

Check the attachment mechanism. Tags must be fastened in a way that prevents inadvertent or accidental removal. Nylon cable ties, brass grommets with wire, and similar secure fasteners are standard. Avoid any attachment method that could slip off or be removed without deliberate effort.

Standardize your tag design across the facility. Consistency matters. When every authorized employee sees the same tag format, color coding, and symbol layout, recognition becomes faster and errors decrease. A facility using several different tag formats from different suppliers introduces unnecessary confusion.

Plan for replenishment. Tags are consumable items. After each lockout event, used tags should be inspected and replaced if worn or damaged. Keep adequate stock on hand so that running low never becomes a reason to skip proper tagging. The Safety Factory manufactures lockout tags and maintenance safety tags in the United States, which means consistent quality and faster restocking compared to overseas sourcing.

Your success indicator for this step: every energy-isolating device in your facility's equipment inventory has a corresponding, correctly specified tag ready for use.

Step 3: Build Your Equipment-Specific LOTO Procedures

One of the most common compliance gaps in LOTO programs is the use of a single generic procedure for multiple pieces of equipment. OSHA 1910.147 is explicit: machine-specific written procedures are required. A procedure that says "shut off power and apply a tag" does not satisfy the standard and does not protect workers who need to know exactly where to isolate energy on a specific machine.

Start with an energy control survey. Walk every piece of equipment in your facility and identify all energy sources and isolation points. For each machine, document the following in a written procedure:

1. Steps to safely shut down the equipment using its normal stopping procedure.

2. The specific location of each energy-isolating device, such as the main disconnect switch, pneumatic shutoff valve, or hydraulic relief valve.

3. Steps to isolate each energy source, in the correct sequence.

4. Steps to apply lockout devices and picture-based lock out tags at each isolation point.

5. Steps to release or restrain stored energy, including bleeding hydraulic pressure, releasing spring tension, blocking suspended parts, and discharging electrical capacitors.

6. Verification steps to confirm zero energy state before work begins.

Connect your tags to your written procedures by specifying which tag corresponds to which isolation point on each machine. This creates a direct link between the physical tag a worker picks up and the procedure they are following.

Assign responsibility clearly. Each machine-specific procedure should name the authorized employee or employees qualified to perform lockout/tagout on that equipment. This removes ambiguity about who is permitted to act.

A practical tip that works well alongside picture-based tags: photograph each energy isolation point and include the image in the written procedure. A worker consulting the procedure can look at the photo, look at the machine, and immediately identify where to apply the tag. This visual pairing reinforces the communication advantage that picture-based tags already provide. For valve-specific isolation steps, see our guide on locking out valves during maintenance.

Your success indicator: every piece of equipment in your facility has a documented, machine-specific LOTO procedure with corresponding tags identified and ready.

Step 4: Train Authorized and Affected Employees

OSHA 1910.147 requires training for two distinct groups of employees, and the content of that training is different for each.

Authorized employees are those who apply and remove lockout/tagout devices. Their training must cover how to read and interpret picture-based lock out tags, the proper application sequence, how to verify zero energy state using appropriate testing equipment, and the correct removal procedure. They must understand not just what to do, but why each step matters.

Affected employees are those who work in the area where LOTO procedures are performed but do not perform the service work themselves. Their training must cover what the tags mean, why they must never remove or bypass a tag, and how to report concerns or unusual situations. Affected employees do not need the same depth of procedural training, but they do need to understand the hazard and their role in not interfering with the process.

Use the picture-based tags themselves as training aids. Walk employees through each pictogram on your facility's tags and confirm they understand what each symbol communicates. Do not assume that a symbol is self-explanatory. A worker who has never seen an electrical bolt symbol in a safety context may not immediately connect it to a life-safety warning without explanation.

Conduct hands-on training at the actual equipment, not only in a classroom or conference room. Authorized employees should practice applying and removing tags on the specific machines they will service. This builds muscle memory and surfaces any confusion about isolation point locations before it matters in a live situation. Understanding OSHA compliant lockout requirements is essential background knowledge for every trainer delivering this content.

Document all training thoroughly. Records should include the date of training, the names of employees trained, the topics covered, and the name of the trainer. These records are subject to OSHA inspection.

Retraining is required whenever a new hazard or piece of equipment is introduced, whenever procedures change, or whenever an employee demonstrates inadequate knowledge or skill. Do not wait for an incident to identify a training gap.

Your success indicator: every authorized and affected employee can correctly identify every pictogram on your facility's lock out tags and explain the corresponding hazard without prompting.

Step 5: Apply Lock Out Tags Correctly — The Proper Sequence

Correct tag application follows a specific sequence. Skipping or reordering steps creates gaps that stored energy can exploit. Follow this process every time, without exception.

1. Notify affected employees. Before shutting down any equipment, inform everyone in the area that the machine will be taken out of service and when work is expected to begin.

2. Identify all energy sources. Consult the machine-specific written LOTO procedure and confirm every energy source and isolation point before touching anything.

3. Shut down the equipment. Use the normal stopping procedure for the machine. Do not use the lockout isolation as the method of shutdown.

4. Isolate all energy sources. Operate each energy-isolating device to the safe or off position. This includes electrical disconnects, pneumatic shutoff valves, hydraulic isolation valves, and any other applicable isolation points.

5. Apply lockout devices and picture-based lock out tags. Where a lockout device can be applied, apply it and secure it with a lock. Apply the picture-based tag directly to the energy-isolating device, or as close to it as physically possible. Fill in all required fields on the tag: the date, the authorized employee's name, and the reason for the lockout. When multiple workers are involved in a single procedure, lockout hasps allow each authorized employee to apply their own personal lock to a single isolation point.

6. Release or restrain stored energy. This step is commonly overlooked and is a well-documented source of LOTO-related incidents. Bleed hydraulic and pneumatic pressure, discharge electrical capacitors, block or restrain parts held up by gravity, and release or block spring-loaded components. Electrical isolation alone does not eliminate all hazards.

7. Verify zero energy state. Use appropriate testing equipment to confirm that no energy remains. Attempt to operate the machine's controls to verify it does not start. Only after verification is it safe to begin work.

Ensure the tag is fully visible and not hidden behind panels, guards, or other equipment. A tag that cannot be seen provides no warning. Never assume a machine is de-energized because it appears off or because someone says it is. Always verify independently.

Your success indicator: the tag is securely attached, fully visible, correctly filled out, and zero energy state has been independently verified before work begins.

Step 6: Remove Tags and Restore Equipment Safely

Tag removal is not simply the reverse of application. It carries its own requirements and sequence, and it is an area where shortcuts create serious risk.

Removal is only authorized once all work is fully complete, all tools and materials have been cleared from the work area, and every employee who was working on or near the equipment is confirmed safely clear. This confirmation must be deliberate, not assumed.

A core OSHA requirement: only the authorized employee who applied the tag may remove it. This rule exists because the person who applied the tag is the one who knows the full scope of the work performed and can confirm it is safe to re-energize. No supervisor, coworker, or manager may remove another employee's tag under normal circumstances.

Follow this removal sequence:

1. Confirm all work is complete and the work area is fully cleared of personnel and materials.

2. Notify affected employees that the equipment will be re-energized and when.

3. Remove lockout devices and tags in reverse isolation order, starting with the last isolation point applied.

4. Restore energy sources in the correct sequence.

5. Verify that the equipment operates correctly before returning it to full service.

There is one exception scenario worth establishing a procedure for in advance: if the authorized employee who applied the tag is unavailable, such as due to an emergency or end of shift, OSHA requires that a documented employer procedure be followed before any tag is removed by another person. This procedure must include verification that the absent employee is not in a hazardous position and notification to that employee before they return to work. Establish this procedure before you need it.

After removal, inspect each tag. Tags that show wear, fading, tearing, or illegible fields must be replaced immediately and should not be reused. Log each lockout event, including the date, equipment involved, authorized employee name, and duration. This log supports your periodic program reviews and provides documentation in the event of an inspection. Proper padlock keying for lockout tagout is another element worth reviewing as part of your removal and re-energization controls.

Your success indicator: equipment is safely re-energized, all tags are accounted for and inspected, and the event is recorded in your log.

Step 7: Audit Your LOTO Program and Maintain Compliance

A LOTO program is not a set-it-and-forget-it system. OSHA 1910.147 requires periodic inspections of energy control procedures at least annually for each procedure in use. These inspections must be performed by an authorized employee other than the one who uses the procedure being reviewed. The goal is an independent check, not a self-assessment.

Use a structured audit checklist to ensure nothing is missed. Key questions to answer during each audit include:

Tag condition: Are all picture-based lock out tags in good physical condition? Are pictograms and text fully legible? Are any tags faded, torn, or otherwise compromised?

Written procedures: Are all procedures current, machine-specific, and reflective of any equipment changes made since the last review? Have any new machines been added without corresponding procedures?

Training records: Are all authorized and affected employees trained? Are records complete with dates and topics? Have any retraining triggers occurred since the last audit?

Practical observation: Are tags being applied and removed correctly in practice? Observing an actual lockout procedure in the field is far more revealing than reviewing paperwork alone. A common audit pitfall is conducting the review entirely on paper without watching how the procedure is actually performed on the floor.

Tag inventory: Is your stock of picture-based lock out tags adequate for your current equipment inventory? Identify any gaps in coverage and reorder before stock runs low. Running out of the correct tag is not a valid reason to delay a LOTO procedure or substitute an incorrect one. Facilities that also rely on circuit breaker lockouts should verify that those devices and their corresponding tags are fully stocked and accounted for during every audit cycle.

Use audit findings directly to improve training. If workers are consistently making errors at a specific step, such as skipping stored energy release or placing tags in locations that are not clearly visible, address that gap directly in the next training session rather than noting it and moving on.

Maintain complete records of every annual inspection, including the date, the procedures reviewed, the inspector's name, and any corrective actions taken. These records demonstrate compliance and provide a clear history of your program's development.

Your success indicator: annual inspection records are complete, all procedures are current, tag inventory is adequate, and no unaddressed compliance gaps remain.

Putting It All Together: Your LOTO Compliance Checklist

Implementing lock out tags with pictures is one of the most practical steps a facility can take to protect workers during maintenance and servicing activities. When picture-based tags are selected correctly, applied in the right sequence, and backed by documented procedures and trained employees, they communicate danger clearly to everyone on the floor, regardless of language or experience level.

Use this checklist to confirm your program is on track:

Energy source inventory: All equipment energy sources are fully identified and documented.

Written procedures: Machine-specific LOTO procedures are documented for every piece of applicable equipment.

Tag selection: The correct picture-based lock out tags are matched to each hazard type and energy source.

Employee training: All authorized and affected employees are trained at the appropriate level, with complete records on file.

Application and removal: Tags are applied and removed following the correct sequence, every time.

Annual audits: Inspections are scheduled, conducted in the field, documented, and used to drive continuous improvement.

A strong LOTO program is not a one-time setup. It requires ongoing maintenance, regular audits, and consistent enforcement at every level of the organization. The Safety Factory has been helping facilities build compliant safety programs for over 80 years, supplying American-made lock out tags, maintenance safety tags, and a complete range of safety supplies. If you need help selecting the right picture-based tags for your equipment or replenishing your LOTO inventory, our team is ready to assist. Learn more about our services.