10 Steps to Build a Zero-Energy Mindset
Posted on: 03/02/2026
10 Steps to Build a Zero-Energy Mindset
Lockout Tagout Tryout (LOTOTO) is a safety procedure that ensures hazardous machinery and energy sources are properly isolated and cannot be re-energised unexpectedly during maintenance or repair work.
For example, a maintenance engineer needs to repair an industrial machine with various blades and moving parts. If the machine were to start up again during maintenance work, it could lead to a serious or potentially fatal injury. That’s why Lockout Tagout Tryout needs to be implemented, to ensure the machine is completely switched off so that situations like this don’t happen.
Following the correct steps builds a zero-energy mindset and a way of thinking that treats safety as the highest priority and demands complete energy isolation before action. A zero-energy mindset helps reduce the chance that the machine is re-energised and minimises the risk of injury or death.
Below are the 10 clear LOTOTO steps every site should follow to achieve a zero-energy mindset.
Step 1: Preparation
Create a plan before starting work.
Step 2: Notify
Step 3: Turn Off
Switch off the equipment using standard procedures and ensure all moving parts have stopped and that the machine is ready for isolation.
Step 4: Isolate
Step 5: Lockout
Step 6: Tagout
Attach a visible tag to each locked point. Tags warn others not to operate the equipment and provide information such as the lock owner’s name, contact details, and expected duration of work.
Step 7: Confirm Zero Energy
Step 8: Tryout
Test the controls to confirm that no energy remains.
Step 9: Completion
During work, continue to observe for any signs of energy buildup or faults. If anything seems unsafe, stop and report it as safety must be maintained throughout the task.
Step 10: Re-Energise
Once work is finished, remove locks and tags carefully.
Building a Zero-Energy Mindset
A zero-energy mindset is a safety culture that businesses must adopt and maintain. It should stay front-of-mind for all staff working on projects, as it is the most effective way to keep engineers safe.
A zero-energy mindset is built on awareness, communication, and consistency. When a business promotes a positive safety culture, everyone understands the importance of following correct procedures.
The zero-energy mindset means:
Following the 10-step LOTOTO process and building a zero-energy mindset helps prevent injuries and saves lives. LOTOTO isn’t something to treat as optional or just another form to fill in. It’s your first line of protection against hazardous energy on site. Skip it and you open the door to accidents, fines, and reputational damage. Put it into practice properly and you build a safer workplace, gain compliance, and give everyone peace of mind.
It takes only one moment of complacency or one small oversight to cause an incident. This is why full commitment to the zero-energy mindset and its processes is important.
Lockout Tagout Tryout (LOTOTO) is a safety procedure that ensures hazardous machinery and energy sources are properly isolated and cannot be re-energised unexpectedly during maintenance or repair work.
For example, a maintenance engineer needs to repair an industrial machine with various blades and moving parts. If the machine were to start up again during maintenance work, it could lead to a serious or potentially fatal injury. That’s why Lockout Tagout Tryout needs to be implemented, to ensure the machine is completely switched off so that situations like this don’t happen.
Following the correct steps builds a zero-energy mindset and a way of thinking that treats safety as the highest priority and demands complete energy isolation before action. A zero-energy mindset helps reduce the chance that the machine is re-energised and minimises the risk of injury or death.
Below are the 10 clear LOTOTO steps every site should follow to achieve a zero-energy mindset.
Step 1: Preparation
Create a plan before starting work.
- Identify every energy source and its isolation point
- Assign an authorised person to control the process
- Make sure everyone understands their role and has the right training
- Prepare the required locks, tags, and equipment
- Complete all permits before starting
Step 2: Notify
- Inform everyone who could be affected by the isolation. This includes operators, maintenance teams, and nearby workers
- Make sure everyone knows the equipment will be locked and that no one should attempt to restart it
Step 3: Turn Off
Switch off the equipment using standard procedures and ensure all moving parts have stopped and that the machine is ready for isolation.
Step 4: Isolate
- Disconnect every source of energy, including electrical, mechanical, hydraulic, or pneumatic power
- Never use an emergency stop button as an isolation method
- Make sure barriers and access points such as gates or interlocked doors are also secured
Step 5: Lockout
- Apply a lock to each isolation point
- Use a hasp if multiple workers need to attach their locks
- Each person should use their own padlock with a unique key
- Contractors should use company-issued locks for consistency
Step 6: Tagout
Attach a visible tag to each locked point. Tags warn others not to operate the equipment and provide information such as the lock owner’s name, contact details, and expected duration of work.
Step 7: Confirm Zero Energy
- Release or drain all stored energy, such as pressure or heat, and confirm it cannot reaccumulate
- Check for hidden energy sources like charged lines, springs, or elevated parts
Step 8: Tryout
Test the controls to confirm that no energy remains.
- All personnel should move to a safe distance during testing
- If the machine stays inactive, it is safe to start work
- If it restarts, stop immediately and investigate before continuing
Step 9: Completion
During work, continue to observe for any signs of energy buildup or faults. If anything seems unsafe, stop and report it as safety must be maintained throughout the task.
Step 10: Re-Energise
Once work is finished, remove locks and tags carefully.
- Each person removes their own lock
- Ensure all tools and parts are cleared, guards are replaced, and everyone is clear of danger zones
- Notify all affected employees before restarting the equipment
Building a Zero-Energy Mindset
A zero-energy mindset is a safety culture that businesses must adopt and maintain. It should stay front-of-mind for all staff working on projects, as it is the most effective way to keep engineers safe.
A zero-energy mindset is built on awareness, communication, and consistency. When a business promotes a positive safety culture, everyone understands the importance of following correct procedures.
The zero-energy mindset means:
- Always assume energy is present until proven otherwise
- Verify isolation through ‘Tryout’, not assumption
- Take personal responsibility by using your own lock and tag
- Never bypass a step for convenience
Following the 10-step LOTOTO process and building a zero-energy mindset helps prevent injuries and saves lives. LOTOTO isn’t something to treat as optional or just another form to fill in. It’s your first line of protection against hazardous energy on site. Skip it and you open the door to accidents, fines, and reputational damage. Put it into practice properly and you build a safer workplace, gain compliance, and give everyone peace of mind.
It takes only one moment of complacency or one small oversight to cause an incident. This is why full commitment to the zero-energy mindset and its processes is important.
