Lockout Card

A Lockout Card covers isolating every energy source on one machine before work starts: what the energy sources are, where each one is isolated, the order to lock out, how to prove zero energy, and the order to restore. It carries the site's near-miss lessons alongside the maker's procedure. For how Lockout Cards fit with the other card types, see Field Cards.

This page shows a complete Lockout Card, explains what each section captures, and then shows how to create one with the InSkill Field Card Creator skill.

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Note

The example is built from fictional AZ Copper Works records and the AZ Machine Works AM-650 manuals. Its pictures are illustrations marked For demo purposes only. A Lockout Card supports the site's lockout program; it does not replace it.

The Example Card

What Each Section Covers

A Lockout Card follows the order of the job itself: know the energy, find the isolation points, lock out, prove zero, and later restore.

Example Questions

These questions were asked in Ask on Copilot (Truck) with the card uploaded, and InSkill GPT answered them correctly. Use them to check the card after you upload it.

How to Create a Lockout Card

Lockout Cards are created in Claude with the InSkill Field Card Creator skill. It takes the energy sources and the lock-out order from the maker's safety chapter, and adds the site's near misses as warnings and field notes. It never shortens or reorders the maker's steps.

Follow these five stages in order:

1. Gather the source data
2. Run the skill
3. Review the card
4. Upload to InSkill
5. Test the card in Ask

Gather the source data

Collect the maker's lockout and stored-energy procedures, and the site's safety records for the machine: stand-downs, near misses and audit findings.

The source for this example is a page of handwritten safety notes:

The skill reads the handwriting and gives every entry a source ID:

Two more records came from the typed field log:

id,date,shift,unit,tech,area,entry
E0003,2026-07-08,Day,B43558,JM,Body,"Prop pin found in its bracket on the left frame rail without the retaining clip lanyard; clip loose on the deck. Replaced clip 650-4189-00. Photo of the storage bracket taken."
E0005,2026-07-12,Day,B43558,JM,Body,"50 h hoist cylinder visual check. Raised empty body to the yellow alignment mark, prop pin installed through frame and body lugs, clip fitted, body lowered onto the pin, locked out. No leaks on either cylinder. Photo of pin installed."

The manual used was the AMW-MP-650-25 Maintenance and Parts Manual (maintenance safety, lockout and tagout, prop pin and stored energy, pages 12 to 14; component locations, page 10).

Run the skill

In Claude, attach the notes, the field log, the manual and the customer logo, and use a prompt like this:

Use the InSkill Field Card Creator skill.

Create a lockout card for the AMW AM-650 haul truck.
- Copilot: Copilot (Truck)
- Site: AZ Copper Works (prefix ACW)
- Keep the card generic to the AM-650: no unit numbers; note model-year differences
- Source: the attached handwritten safety notes and field log, July to September 2026
- Take the energy sources, isolation points and lock-out order from the attached
  AMW-MP-650-25 manual, pages 12 to 14, and cite the page; never shorten or
  reorder the maker's steps
- Add each near miss as a warning and a field note
- Tag any restore step the manual doesn't give as To confirm
- Header: the attached AZ Machine Works logo

Review the card

Before you upload the card, check:

• Every page reads cleanly, no heading is stranded at the bottom of a page, and the card ID fits the header.
• Every field value appears in the source records, and every source ID on the card exists.
• Every value taken from the manual cites its page.
• The To be confirmed list names every gap, and who should close it.
• The settings file has InSkill GPT Answers, App and Web all on.
• The site safety lead approves the card, including every To confirm step, before it is uploaded.

Upload to InSkill

Field cards are uploaded with InSkill GPT Answers, App and Web all on. With App and Web off, InSkill GPT still uses a card, but doesn't show it as a resource in the answer.

1. Open the copilot, here Copilot (Truck), and open its Resources tab.
2. Click Bulk Upload and add the PDF.
3. Under Configure defaults for uploaded files, leave Published on. Under Visibility, leave App, Web and InSkill GPT Answers selected. Under InSkill GPT, leave Searchable and Parse selected.
4. Click Create 1 Resources, then Done.
5. Open the new resource and set Name, Keywords and Description from the settings file. Leave Prompt empty. Click Save. See Editing Resource Attributes.

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Note

Claude can do step 5 for you through the InSkill MCP Server: ask it to apply the .inskill.json settings file to the uploaded resource.

In this example the resource name is Field Card (Lockout) | Lockout and tagout: AM-650 haul truck.

Test the card in Ask

Ask the example questions in Ask on the copilot and check the answers against the card. Check that every answer gives the full lock-out order, never a shortened one.

Output Reference

Files

The skill writes two files for each card:

The skill writes the card in English, even when the source records are in another language. It writes another language version, for example ACW-AZMachineWorks-AM650-Truck-O-001-ES.pdf, only when you ask for one. On request, it also delivers a kit with the template, builder, content files and images, so the card can be rebuilt after edits.

Card ID

Every card ID follows the pattern <Site>-<Brand>-<Model>-<MachineType>-<Code>-<Number>, and each language version adds a suffix:

Value tags

Every value on the card is tagged so Technicians and InSkill GPT know how far to trust it:

Status, version and review

Settings file

The settings file for this Lockout Card:

{
  "card_id": "ACW-AZMachineWorks-AM650-Truck-O-001",
  "resource_title": "Field Card (Lockout) | Lockout and tagout: AM-650 haul truck",
  "language": "en",
  "base_language": "en",
  "is_base": true,
  "translation_group": "ACW-AZMachineWorks-AM650-Truck-O-001",
  "card_type": "lockout",
  "status": "field",
  "version": "0.1",
  "review_date": "2027-01-29",
  "owner": "To be assigned",
  "copilot": "Copilot (Truck)",
  "visibility": {"vis_mvn": true, "vis_web": true, "vis_app": true},
  "keywords": ["lockout", "tagout", "LOTO", "lock out tag out", "isolation", "battery disconnect", "master switch", "ground-level shutdown", "DO NOT OPERATE tag", "personal lock", "accumulator discharge", "bleed down brakes", "zero energy", "prop pin", "working under the body", "AM-650"],
  "mvn_desc": "Lockout and tagout: AM-650 haul truck. Lockout card for the AMW AM-650 rigid haul truck.",
  "source_entries": "E0003, E0005, E0014, E0021, E0024, E0036, E0037 (AZ Copper Works field log, Jul–Sep 2026, fictional demo data). Manuals: MP pp. 10, 12–14, 35–36. SM = AMW-SM-650-25 Rev. A Service Manual, MP = AMW-MP-650-25 Rev. A Maintenance and Parts Manual.",
  "file": "ACW-AZMachineWorks-AM650-Truck-O-001-EN.pdf"
}