Why Workers Keep Dying Even With Lockout/Tagout Rules in Place

The Hidden Human Factors Behind Persistent LOTO Fatalities

Across New York and throughout the country, industrial workplaces rely on strict safety protocols to protect employees from hazardous equipment and machinery. One of the most important of these safeguards is the lockout/tagout (LOTO) procedure. This process is designed to prevent machinery from starting up or releasing stored energy while maintenance or repairs are in progress.

Despite OSHA’s lockout/tagout standards being in place for decades, LOTO violations continue to rank among the most frequently cited workplace safety failures. Worse still, serious injuries and deaths tied to uncontrolled energy keep occurring. The question is not whether employers understand the rules, but why so many still fail to keep workers safe.

When these tragedies happen, injured employees and grieving families often turn to a New York workers’ compensation lawyer for answers and support. Having an experienced attorney on your side can make all the difference in holding employers accountable and securing the benefits you need to move forward. Our firm stands ready to help workers across New York navigate these complex claims and fight for the justice they deserve.

What Lockout/Tagout Procedures Are Meant to Prevent

LOTO requirements are designed to stop unexpected movements or energy discharges in equipment that could crush, cut, electrocute, or otherwise harm workers. OSHA’s standards under 1910.147 spell out the steps that employers must take, including:

• Identifying all energy sources linked to a machine
• Shutting down and isolating those sources
• Locking and tagging controls so they cannot be reactivated
• Verifying that all energy is controlled before work begins

When done correctly, these procedures prevent tragedies like conveyor belts starting up unexpectedly or pressurized systems suddenly releasing, both of which can cause devastating injuries.

Why LOTO Accidents Still Happen (It’s Not Always About Equipment)

Many companies have written lockout/tagout programs and purchased the necessary locks and tags. However, serious incidents continue to occur because compliance often breaks down at the human level. Even a robust safety manual cannot overcome a workplace culture that treats LOTO like an inconvenience.

1. Inadequate or Inconsistent Training

OSHA investigations frequently find that employees were either not properly trained on LOTO or received only surface-level instruction. When workers do not understand how energy can still be present in a system or how to isolate it fully, they are more likely to skip steps or make errors. True compliance requires repeated, hands-on training that clarifies the reasons behind each step.

2. Pressure to Maintain Production

In many New York workplaces, particularly in high-demand manufacturing or construction environments, there is intense pressure to keep operations moving. Workers under time constraints may bypass lockout procedures to avoid delays. Supervisors may look the other way if locking out equipment means missing a deadline. This mindset puts speed over safety, setting the stage for life-changing injuries.

3. Dangerous Assumptions and Complacency

When employees handle the same machinery every day, familiarity can breed carelessness. They might think they know exactly when a machine is safe to work on and decide a quick adjustment does not require a full lockout. Unfortunately, all it takes is one oversight or a coworker re-energizing a system to turn a routine shortcut into a fatal mistake.

What Happens When LOTO Fails?

When lockout/tagout protocols are not followed, the consequences can be catastrophic. Some of the most common injuries from LOTO failures include:

• Amputations from machinery unexpectedly cycling or cutting
• Crushing injuries as a result of moving parts trap workers
• Burns and electrocution from sudden releases of electrical energy
• Eye and head trauma from pressurized lines bursting

In the worst cases, employees lose their lives. Families are left devastated, facing not only the grief of a loved one’s death but also sudden financial insecurity.

How New York Employers Can Strengthen Their Safety Culture

Preventing these tragedies requires more than just issuing locks and tags. Employers must foster a culture where safety truly takes priority. That includes:

• Providing detailed, frequent training that covers both the mechanics and the life-saving purpose behind LOTO
• Ensuring supervisors enforce lockout procedures, even if it temporarily slows production
• Encouraging workers to speak up without fear when they see unsafe shortcuts
• Recognizing and rewarding employees who prioritize proper safety steps

Leadership plays a crucial role. When management is willing to halt operations for safety and openly supports workers who follow lockout rules, it signals that lives matter more than the bottom line.

What Injured Workers and Grieving Families Need to Know About Their Rights

Despite all the rules in place, workers continue to suffer serious harm due to LOTO failures in New York. If you or a loved one was hurt because machinery was not properly locked out, you have rights. In most cases, you are eligible for workers’ compensation benefits that cover medical bills and partial lost wages.

However, if the accident resulted from extreme negligence, third-party liability may also come into play. For example, if an outside contractor failed to lock out equipment on a shared jobsite, you may have grounds to pursue additional compensation beyond workers’ comp.

Talk to Experienced New York Attorneys About Workplace Safety Failures

At Pasternack Tilker Ziegler Walsh Stanton & Romano LLP, our attorneys have been fighting for injured New Yorkers for over 90 years. We understand the life-altering impact that serious workplace accidents have on employees and their families. Whether your case involves a LOTO violation, another form of industrial negligence, or questions about your rights after a severe injury, our team is here to guide you.

Do not wait to find out where you stand. The sooner you reach out to us, the sooner we can help protect your rights and secure the benefits or compensation you deserve. Contact us today for a free, confidential consultation.

"I am incredibly grateful for the exceptional representation I received from this law firm during my workers' compensation case. From our very first meeting, I felt completely supported and confident that I had chosen the right team to advocate for me." — Patrick, ⭐⭐⭐⭐⭐