Setting a New Safety Standard with Digital Lockout/Tagout

Digital LOTO systems and procedures are driving beneficial safety enhancements. How do companies train employees in this important technological shift?

• By Herbert Post
• Aug 01, 2024

The transformation of traditional LOTO practices into digital lockout tagout systems is revolutionizing workplace safety. This shift aims to enhance efficiency and minimize errors in the lockout tagout procedure. It’s a response to the rising need for better safety standards.

One reason for this transformation could be the increasing number of cited violations for lockout tagout. According to OSHA’s Top 10 Most Cited Standards, cited violations for lockout/tagout increased from 2,139 in 2022 to 2,539 in 2023, maintaining its position as the 6th most cited. This indicates a persistent issue that needs a modern solution.

Another reason is the challenges and limitations of traditional lockout tagout. These include:

• Human error: Mistakes in manual processes can lead to accidents.

• Time-consuming processes: Traditional methods often take longer, affecting productivity.

• Inadequate documentation: Keeping track of LOTO events manually can lead to incomplete records.

• Compliance difficulties: Ensuring all procedures meet regulations can be harder with manual systems.

• Limited monitoring: Traditional LOTO lacks real-time oversight, making it harder to spot issues quickly.

What is Digital LOTO?

Digital lockout tagout is an advanced system that uses digital technology to enhance the traditional lockout tagout procedure for improved safety and efficiency.

Key features of digital lockout tagout systems include real-time monitoring, automated documentation, and remote access. These systems allow safety managers to track LOTO activities in real-time, ensuring immediate response to any issues. They automatically record every lockout event, reducing the risk of incomplete records. Additionally, managers can access and control LOTO systems remotely, providing flexibility and quick action. These systems are also designed to easily meet regulatory standards, simplifying audits and inspections.

Benefits of Digital Lockout Tagout Procedures

Enhanced safety and efficiency: Digital lockout tagout systems improve overall safety by reducing risks associated with manual errors. They also streamline the lockout tagout procedure, saving time and increasing productivity. For example, if a machine needs maintenance, a worker can quickly initiate a digital LOTO procedure. The system ensures all safety steps are followed automatically, and the machine is safely locked out in minutes, reducing downtime and potential hazards.

Real-time monitoring and reporting: Digital LOTO systems offer real-time tracking of lockout activities, providing instant updates and alerts. This allows for immediate response to any issues that arise. For instance, if a lock is removed without authorization, the system instantly notifies the safety manager. They can then take quick action to investigate and address the situation, preventing potential accidents.

Reduced human error: Automating the lockout/tagout process minimizes mistakes that can occur with manual procedures. Digitized lockout tagout systems ensure every step is accurately completed. For example, a worker might forget to tag a locked-out machine, but with a digital system, this step cannot be skipped. The system will flag any incomplete steps, ensuring the procedure is fully followed and reducing the risk of accidents.

Easier compliance with regulations: Digital lockout tagout systems are designed to meet safety standards more easily, making it simpler to comply with regulations. This is crucial for passing safety audits and inspections. For example, during an OSHA inspection, the digital system can quickly generate a report showing all lockout activities and compliance status, making the audit process smoother and more efficient.

Better record-keeping: Digital LOTO procedures automatically document every lockout event, ensuring comprehensive and accurate records. This helps in tracking and reviewing safety practices over time. For instance, if a safety manager needs to review past lockout events to identify patterns or issues, they can easily access detailed records from the digital system, providing valuable insights for improving safety protocols.

How to Train Employees for Digitized LOTO

Training employees on digitized lockout tagout is important in ensuring the safe and effective implementation of this technology. Here are some methods that can be implemented in training employees for digitized LOTO:

• Online courses: Online courses provide flexibility, allowing employees to learn at their own pace and on their own schedule. These courses can include video tutorials, interactive modules, and quizzes to reinforce learning. For example, an online course might walk an employee through the steps of the digital lockout tagout process, explaining each part in detail and providing virtual demonstrations. Employees can revisit the material as needed, ensuring they fully understand the procedures. This method is especially useful for reaching employees in different locations or those with varying schedules.

• Hands-on workshops: Hands-on workshops offer practical, in-person training where employees can practice using the digital lockout tagout systems. These workshops are led by experienced trainers who can provide immediate feedback and answer questions. For instance, a workshop might involve setting up a mock lockout scenario where employees use the digital tools to secure and tag equipment. This real-world practice helps employees build confidence and competence in using the new technology.

• Interactive simulations: Interactive simulations allow employees to engage in realistic scenarios in a controlled environment. These simulations can mimic real-life situations where employees must use the digital LOTO procedure to lock out equipment safely. For example, a simulation might present a series of virtual machines that require lockout, and employees must navigate the digital interface to complete the process correctly. This method helps employees understand how to handle unexpected situations and reinforces their problem-solving skills.

Ongoing education ensures that employees stay current with the latest developments in digital lockout tagout technology and procedures. Regular updates and refresher courses can help employees maintain their skills and knowledge. Continuous education also helps reinforce the importance of safety and compliance, promoting a culture of ongoing learning and improvement within the organization.

Overcoming Challenges in Digital LOTO Adoption

Adopting digital lockout tagout systems can present several challenges, but these can be effectively managed with the right strategies.

Addressing resistance to change: Employees may be hesitant to adopt new technologies, preferring the familiarity of traditional lockout/tagout methods. To overcome this, it’s important to communicate the benefits of the digital lockout tagout system clearly, such as improved safety and efficiency. Providing comprehensive training and support can help ease the transition and build confidence in using the new system. Encouraging feedback and involving employees in the implementation process can also foster acceptance and cooperation.

Ensuring technology compatibility: Integrating digital LOTO procedures with existing systems and equipment can be challenging. It’s essential to assess the current technology infrastructure and ensure that the new digitized lockout tagout system is compatible. Working closely with the technology provider can help address any compatibility issues and facilitate a smooth integration.

Managing costs and budget: Implementing a digital lockout tagout system can be costly, including the expenses for new equipment, software, and training. To manage these costs, it’s important to develop a clear budget and explore funding options or grants available for safety improvements. Conducting a cost-benefit analysis can help justify the investment by highlighting long-term savings from reduced accidents and improved efficiency.

Is Digitized Lockout Tagout Setting a New Safety Standard?

While the benefits of digital lockout tagout systems are clear, it’s important to remember that their effectiveness hinges on the quality of the data and procedures put into them. As the saying goes, “Garbage In = Garbage Out.”

To ensure a successful digital lockout tagout system, involving the most experienced Subject Matter Experts and knowledgeable employees is essential. These experts can accurately identify the lockout points and determine the correct order for locking out machines or equipment. The primary advantage of a digital solution is its ability to ensure less human error through consistent lockouts—the same order and the same LOTO points every time for each machine.

Adopting digitized lockout tagout systems is about leveraging new technology, integrating expert knowledge and ensuring meticulous planning and execution. By doing so, companies can set a new safety standard that prioritizes the well-being of every employee and fosters a proactive safety culture.

This article originally appeared in the July/August 2024 issue of Occupational Health & Safety.