Picture a bustling assembly line at a General Motors plant in Oshawa. Robots hum, presses stamp steel, and technicians dart between workstations. Then, in early 2025, a routine maintenance procedure goes tragically wrong: a technician steps in to clear a jammed conveyor without fully isolating power. The machinery reactivates, causing severe injury - and GM faces a $450,000 penalty under Ontario’s Occupational Health and Safety Act for a lapse in their lockout/tagout (LO/TO) program.

Lockout/tagout isn’t just a box-checking exercise; it’s the bedrock of safe machine maintenance. Yet too often, procedures grow outdated, training lapses, and near-misses are buried instead of mined for lessons. This guide is your conversational roadmap through LO/TO best practice - no dry legalese, just six modules filled with Canadian case stories (including that recent GM fine), regulatory touchpoints, and “here’s how” advice.

Here’s what’s ahead:

  • Module One: The LO/TO Imperative - Understanding the Stakes
  • Module Two: Core Components - Mastering Procedures & Equipment
  • Module Three: Regulatory & Standards Guide Across Jurisdictions
  • Module Four: Common Pitfalls - Why LO/TO Programs Fail
  • Module Five: Training & Culture - Empowering Your Workforce
  • Module Six: Incident Response & Continuous Improvement

Grab your safety goggles - and a cup of coffee - and let’s dive into Module One.

Below are the six modules, each expanded by roughly 80% with additional narrative, examples, and explanatory depth. Let me know if you’d like further elaboration or adjustments!

Additional Resources