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A Hub for Real-World
LOTO Revelations

Get firsthand insights into LOTO challenges,
violations, and lessons directly from the field.

Lockout Tagout Case Studies

Why do you think accidents occur in industries? Is it the workers' fault or an error on their supervisors' part? Discover how workers became victims of severe accidents through these elaborated case studies.

Each of these case studies, presented before you, results from Lockout Tagout inspections derived from compliance interpretations, court decisions, review commission, and inspection files.

Whether you are an employer, employee, EHS supervisor or a health and safety enthusiast, these Lockout Tagout case studies are sure to improve your knowledge and ingrain the importance of LOTO in your minds.

Why Accidents happen - LOTO Case Studies

Fatal Accident in Petrochemical Company | LOTO Case Study 1

Fatal Accident in Petrochemical Company | LOTO Case Study 1

Incident reported in a petrochemical company, resulted in the death of two supervisors. To read full case study, download it FREE.


A Maintenance Worker has a fatal fall off the Ladder | LOTO Case Study 2

A Maintenance Worker has a fatal fall off the Ladder | LOTO Case Study 2

Death of maintenance worker exposed to electrical hazards. To read full case study, download it FREE.


Accident at Amusement Park : Severe Injuries to the Worker | LOTO Case Study 3

Accident at Amusement Park : Severe Injuries to the Worker | LOTO Case Study 3

Innocent electrician severely injured in an amusement park in Wisconsin, United States. To read full case study, download it FREE.


The Sudden Release of Hazardous Energy, Injures Millwright | LOTO Case Study 4

The Sudden Release of Hazardous Energy, Injures Millwright | LOTO Case Study 4

A Millwright was fatally injured because of an uncontrolled release of energy while repairing a log debarking machine. To read full case study, download it FREE.


Serious Injury to a Millwright : LOTO Procedures not Followed | LOTO Case Study 5

Serious Injury to a Millwright : LOTO Procedures not Followed | LOTO Case Study 5

A millwright died because he failed to follow the adequate lockout procedures and verify the machine's isolation and de-energisation. To read full case study, download it FREE.


Plywood Industry Employee's Hand Amputated | LOTO Case Study 6

Plywood Industry Employee's Hand Amputated | LOTO Case Study 6

A plywood industry employee had his hand amputated as Lockout Tagout procedures were not followed. To read full case study, download it FREE.


Sudden Energization of a Steel Mill Car : Casualty | LOTO Case Study 7

Sudden Energization of a Steel Mill Car : Casualty | LOTO Case Study 7

Serious injury to maintenance worker due to the rolling of nearby machine! To read full case study, download it FREE.


Crushed by a Hydraulic Door : Worker Dies! | LOTO Case Study 8

Crushed by a Hydraulic Door : Worker Dies! | LOTO Case Study 8

A welder dies after being crushed by a hydraulic door on a scrap metal shredding machine. To read full case study, download it FREE.


Sharp Blades of a Cutting Machine Kills Worker at Site | LOTO Case Study 9

Sharp Blades of a Cutting Machine Kills Worker at Site | LOTO Case Study 9

Worker died while changing blades on a cutting machine at site. To read full case study, download it FREE.


Rotating Augers Cause Fatality | LOTO Case Study 10

Rotating Augers Cause Fatality | LOTO Case Study 10

Employee got crushed between the rotating augers in a machine while cleaning and sanitizing. To read full case study, download it FREE.


Failing to De-energise Equipment Leads to an Accident | LOTO Case Study 11

Failing to De-energise Equipment Leads to an Accident | LOTO Case Study 11

Injury occurred to a worker at an ETP Plant in the brewery industry. To read full case study, download it FREE.


Serious Traumatic Injury Due to Inadvertent Machine Start-up | LOTO Case Study 12

Serious Traumatic Injury Due to Inadvertent Machine Start-up | LOTO Case Study 12

Employee broke his ankle while servicing a jammed roller, as he jumped from a conveyor at height. To read full case study, download it FREE.


Severe Accident Averted through a near miss at a Laminate Industry | LOTO Case Study 13

Severe Accident Averted through a near miss at a Laminate Industry | LOTO Case Study 13

A Laminate Industry worker, fortunately, saved from an accident during machine cleaning. To read full case study, download it FREE.


Why should you read the Lockout Tagout case studies?

Case studies are used in various different sectors because of their numerous benefits.

They play a key role in teaching facility staff about the importance of Lockout Tagout procedures and the consequences of their negligent behaviour.

They present information engagingly and dramatically that grabs the reader's attention, making their learning process much more interesting. They deal with applied, practical and real-life issues that challenge workers on the job.

These case studies, in particular, provide a way of concentrating on a particular incident, hazard, unsafe act, etc. Analysing what happened, why it happened, and how it could have been prevented. With the help of context and detailed data, workers can analyse what they would and would not do in a particular situation, why, and how.

It encourages interaction between trainers and trainees; enhancing understanding of unsafe acts and conditions during energy control procedures, stimulating readers to think and solve problems by examining information, considering alternatives, and deciding the safest course of action for foolproof isolation.

Investigative Approach:

Like a workplace accident investigation, an accident case study dissects the events leading up to the accident and helps workers to:

• Identify potential hazardous energies
• Understand accident causes mistakes and errors
• Discuss possible preventive measures with their peers and supervisors
• Determine the best methods for preventing a similar accident
• Apply the gathered information to safety issues in the workplace
• Transfer the analysis, problem-solving, and decision-making skills learned during the case study process to real situations on the job

With all these benefits, it's easy to see why case studies are a popular format for safety and health training in Energy Isolation Management.

Following each case study scenario, you can stride through a sequence of analytical recommendations and make decisions concerning the proper application of the Lockout Tagout standards.

We are happy to make Lockout Tagout Accident Case Studies accessible for all. Watch for future updates and many more interactive Lockout Tagout scenarios.

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In Lockout Tagout, every detail counts. Let’s discuss yours.

Hi! I'm Pyush, the Technical Director at E-Square

Please write to me here if you have any questions or require any kind of assistance. We will get back with an answer ASAP !


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