2026 Manufacturing Safety: OSHA Lockout/Tagout Regulations

The modern manufacturing plant looks different than it did 5 years ago. Technology and AI are changing workplaces rapidly.

However human safety remains the top priority on every factory floor.

Making a manufacturing plant safe requires laws and regulations. It also needs technology that can protect the employees operating heavy machinery.

In this article we are going to highlight common hazards and what managers can do to mitigate them.

The Top 10 Common Manufacturing Hazards

Here are the most common risks that Safety Managers should be aware of and taking steps to mitigate.

1. Uncontrolled hazardous energy (Lockout/Tagout Failures)

2. Inadequate machine guarding

3. Slips, trips, and falls

4. Fires

5. Power outages

6. Emergency evacuation

7. Chemical exposure

8. Hearing damage from noise

9. Overexertion and repetitive motion

10. Heavy equipment accidents (forklifts, etc)

There are hundreds of hazards that need to be mitigated. The top concerns for most factories are machine guarding and Lockout/Tagout.

Machine Guarding vs. Lockout/Tagout

These two terms are often thrown around in the manufacturing industry. 

Simply, machine guarding refers to barriers between dangerous machine parts and operators. Lockout/Tagout is a system that stops machines from working when they shouldn’t.

Machine guarding procedures include things like push blocks, safety goggles, and physical barriers. These are critical in keeping workers safe.

Machine guarding requires rules from the safety manager and compliance from employees. If either party is irresponsible, injury is inevitable.

Lockout/Tagout, also known as LOTO, is more automatic than machine guarding. With LOTO as long as the system is in place, injury cannot occur.

A Lockout/Tagout system stops power from going to a machine when it shouldn’t. 

LOTO solutions are sometimes installed in the machines themselves. To keep it simple, install an external LOTO device to every machine. This ensures safety for every operator.

Understanding Lockout/Tagout

Lockout/Tagout is one of the most misunderstood aspects of machine safety. As a safety system it is most often used during repairs, but there is more LOTO can do.

What is the purpose of Lockout/Tagout?

LOTO physically prevents any machine from turning on accidentally. It does not allow power to the device until the operator deactivates the system. After, they can activate the machine.

When should Lockout/Tagout be used?

Every machine should have a LOTO system installed. Lockout/Tagout should be enabled during maintenance of the machine. 

LOTO systems will also activate during a power outage. This stops power outages cutting power and surging suddenly, activating the machine.

The best Lockout/Tagout devices will also activate to alarms. These systems hear the sound of a fire or emergency alarm, then automatically shutoff. 

In short, LOTO should be used on every machine, in every manufacturing plant. 

If your plant does not have complete LOTO systems, contact our team for a quote today.

Lockout/Tagout & Machine Guarding Examples

Machine Guarding Examples

Example 1. Using a push block to guide wood through a saw safely

Example 2. Guard walls that prevent hands or fingers from entering moving machine parts

Example 3. Presence sensing devices to stop machine presses if foreign objects are detected.

Lockout/Tagout Examples

Example 1. When performing a repair on a conveyor LOTO stops the machine from starting

Example 2. A fire alarm sounds, shutting off the machine and allowing the operator to evacuate. When safe to return, the operator manually resets the system to continue working.

Example 3. The power goes out at the facility. When the power suddenly returns all machines are still off because of LOTO. Operators can manually reset the device safely.

Upgrade Your Factory: Modern Industrial Safety

Compliance to the OSHA regulations for your plant guarantees you don’t receive any fines. 

However, it also ensures your employees are safer and your plant is more efficient.

As you improve the safety of your factory you will find reduced downtime and zero OSHA citations. 

You will have lower worker’s comp insurance premiums and a stronger work culture.

If your machines do not have machine guarding procedures, now is the time to change that. Safe employees are employees that can work effectively.

If your plant does not have LOTO systems in/on every machine, you should install them. 

If your LOTO systems only function for maintenance it’s time to upgrade. Lockout/Tagout is best used for emergencies and power outages as well.

SpinSafe is the #1 plug-and-play Lockout/Tagout device on the market. 

SpinSafe is FireAvert's entry to the manufacturing industry. The technology behind this device comes from the Auto Shutoff device as seen on Shark Tank.

FireAvert's Auto Shutoff is the only fire prevention product on the market. The SpinSafe device is also the most affordable and comprehensive LOTO device available.

For bulk pricing, get a free quote today!