Most facilities fail their own LOTO audit and do not know it. The reason is simple: the program was written when the plant had fewer machines, or by someone who left two plant managers ago, and no one has mapped the current equipment against the current standard since. Our on-site gap analysis fixes that. Every deficiency, mapped to the specific sub-clause of 1910.147 and ANSI Z244.1, delivered as a written report.
What It Is
Most facilities believe their LOTO program is compliant. Most are wrong in at least one significant area. An on-site gap analysis is the only reliable way to know.
Our certified safety specialists walk your facility, examine every piece of equipment with hazardous energy sources, and evaluate existing procedures, placards, documentation, and training records against 1910.147, ANSI Z244.1, and applicable ISO standards.
What you get back is not a general recommendation. It is a machine-by-machine, requirement-by-requirement breakdown of what is compliant, what is not, and exactly what needs to be corrected. Every finding is mapped to the specific regulatory citation so you know the exposure you are carrying.
Who needs this most: Facilities that have never had a formal LOTO assessment, facilities where procedures were written internally without regulatory expertise, or facilities that recently added new equipment or automation.
What a typical finding looks like: The last gap analysis we ran found 43 energy-isolating devices on the plant floor that had no corresponding written procedure. The facility had been operating under the assumption that their "master procedure" covered everything. It didn't. Counts like that are common on first assessments, which is why a walkthrough before the inspector arrives is almost always worth more than a remediation after.
Assessment Options
Choose the assessment that fits, from a targeted signage review to a full regulatory crosswalk of your entire safety operation.
Targeted review of your safety signage
Full review of your safety operation
Timing
If you know an inspection is coming, or you are in an industry that gets inspected regularly, a gap analysis lets you identify and correct findings before the inspector does. Remediation always costs less than citations.
New facilities often start with informal or incomplete LOTO programs. A gap analysis establishes the baseline and flags everything that needs to be built out before operations scale.
Robotic cells and automated systems bring LOTO and access control requirements that existing programs rarely address. Adding automation without updating your LOTO program creates immediate compliance gaps.
When leadership pushes for standardized safety practices across all facilities, a gap analysis at each location gives you the data to build a centralized remediation plan.
An incident involving hazardous energy almost always reveals a gap in the LOTO program. A formal gap analysis documents what went wrong and provides the corrective action framework required for internal and regulatory purposes.
A gap analysis gives you the documented evidence you need to justify capital investment in safety improvements. It converts compliance risk into business risk that leadership understands.
Deliverables
The assessment is not a visit and a verbal debrief. You receive a formal, documented report that doubles as a compliance roadmap and an internal justification document.
After report delivery, we are available to handle remediation end to end, from building custom placards to completing the full-service LOTO program. Or you can take the report and act on it internally.
What most facilities discover: The majority of facilities we assess have three consistent gaps. Paper or laminated placards that do not meet durability standards. Incomplete procedures for multi-energy equipment. No compliant access placards for robotic or automated systems.
Request a gap analysis and get a clear picture of your compliance exposure before your next audit or inspection.
Schedule a Gap Analysisor call (847) 232-6067