Connected Lockout/Tagout: Smarter, Faster, but Still Physical

As connected safety technologies expand into more workplaces, LOTO systems are evolving to offer greater visibility, accountability and compliance support—but they also raise new questions.

• By David Kopf
• Sep 08, 2025

Lockout/tagout is one of the most time-tested methods of keeping workers safe around machinery. By physically isolating energy sources with a lock and tag, employers prevent sudden start-ups that could cause serious injury or worse. The fundamentals of LOTO haven’t changed much in decades. But as digital technology reshapes many aspects of safety, a new approach is emerging: connected lockout/tagout. 

Connected LOTO combines traditional locks and tags with digital oversight tools such as Bluetooth-enabled padlocks, QR codes, cloud dashboards, and mobile apps. The promise is straightforward: more visibility into who is locked out, stronger accountability through digital records, and fewer delays waiting on paperwork or in-person checks. Supervisors can see real-time status from anywhere, audits are easier to complete, and the data generated can highlight inefficiencies in maintenance workflows. 

Yet for all its promise, connected LOTO raises important questions. OSHA’s control of hazardous energy standard, 29 CFR 1910.147, still requires physical locks on energy sources. No matter how sophisticated the digital tools, they can only supplement, not replace, the padlock. 

What Connected LOTO Means 

In practice, a connected system looks much like a traditional lockout program, but with a digital overlay. A worker applies a lock to an energy source, but instead of filling out paperwork or relying on memory, they use a mobile app to walk through each step of the procedure. The lock itself may be embedded with a Bluetooth chip or paired with a QR code. Scanning it records who applied it, when, and where. 

Supervisors no longer need to physically walk to every machine to verify lockout status. Instead, they can log into a dashboard to see which machines are under maintenance, who holds the keys, and how long the equipment has been down. For organizations with multiple facilities or dispersed maintenance teams, that visibility is especially attractive. 

The driving force behind connected LOTO is not novelty, but efficiency. Many facilities are looking for ways to streamline safety procedures without sacrificing compliance. Digital lockout systems promise to cut delays, improve documentation, and integrate lockout data into larger maintenance and safety management systems. 

Opportunities and Cautions 

Advocates of connected systems point to clear benefits. The most obvious is real-time tracking. With digital logging, supervisors can instantly see which locks are in place and which machines are safe to service. Every lockout action creates a digital footprint, giving managers confidence that steps haven’t been skipped. Over time, this creates a searchable record that simplifies annual audits and compliance reviews. 

Another benefit is accountability. Digital logs can help ensure that only authorized workers remove their own locks, closing a common gap in paper-based systems. Many vendors also highlight efficiency: equipment may return to service faster when lockout status is visible to everyone involved, reducing costly downtime. 

But the pitfalls are equally real. Digital locks and dashboards depend on connectivity and power. A dead battery or dropped Wi-Fi signal could delay work, so backup procedures remain essential. Cybersecurity is also a concern. Network-connected locks must be protected against unauthorized access, and safety professionals may find themselves working closely with IT teams in new ways. But these are concerns universal to many applications of Internet of Things-type innovations to workplace safety. 

Cost is another factor. Connected padlocks, mobile licenses, and cloud subscriptions can add up, especially in large facilities. Some safety managers also worry about human behavior. Technology can guide every step, but if a worker forgets to physically apply a lock—or becomes overly reliant on the software—the system fails its purpose. 

Market Players and Technology 

Several companies have entered the connected LOTO space, each offering variations on the concept. Some emphasize hardware, while others focus on workflow software. Here are a few of the active players in today’s market: 

• Master Lock – cLOTO. Combines connected padlocks and QR-coded devices with mobile and desktop apps for procedure management and audit trails (masterlock.com.) 

• Brady – LINK360. A software-driven platform for creating, managing, and verifying lockout/tagout procedures across sites (bradyid.com.) 

• SEAM Group (ABB) – ViewPoint Digital LOTO. Uses QR code scanning at the point of work for real-time verification and oversight (seamgroup.com.) 

• BoxLock. Offers cellular-connected padlocks with cloud logging and integrations with project management tools (boxlock.io.) 

• eGeeTouch. Produces electronic LOTO padlocks with NFC/Bluetooth control, cloud authentication, and audit logging (egeetouch.com.) 

• Smartlox. Provides Bluetooth-enabled padlocks paired with a mobile/cloud platform, targeting industries from manufacturing to rail.( smartlox.io.) 

• GOARC. Offers a digital LOTO management module within its Control-of-Work safety suite, with IoT and ERP integration (go-arc.com.) 

• Rockwell Automation. Embeds digital LOTO oversight into its FactoryTalk and ScanESC systems, aligning hazardous energy control with automation (rockwellautomation.com.) 

Compliance and Worker Safety 

One of the most pressing questions is whether connected LOTO complies with OSHA. The answer is yes, if implemented properly. OSHA’s hazardous energy control standard mandates that energy sources must be physically isolated with locks that are durable, standardized, and identifiable. Connected locks can meet those requirements, but only if they function as true physical lockout devices. 

What connected systems add is oversight. They can make it easier to demonstrate compliance during inspections, simplify annual audits, and provide digital proof that procedures are followed. But they cannot eliminate the basics. Workers must still receive training, procedures must still be inspected annually, and employers must still ensure that locks are under the exclusive control of the employee who applied them. 

In this sense, connected LOTO should be viewed as supplemental, not substitutional. The digital layer adds value through data, but it cannot replace the lock and key. 

What’s Next? 

Connected lockout/tagout is part of a broader wave of digital safety tools, from connected PPE to real-time monitoring systems. As workplaces embrace Industry 4.0, it’s not surprising that LOTO is following suit. 

The future may bring deeper integration. Lockout data could feed into predictive maintenance programs, alerting supervisors when certain machines require frequent intervention. Artificial intelligence could analyze lockout trends to spot inefficiencies. Locks may eventually communicate directly with machinery or facility systems, closing loops automatically. 

Still, the balance will always matter. Digital tools can make LOTO smarter, but they should never distract from the physical act of isolating hazardous energy. 

Practical Takeaways  

For safety professionals, the message is clear. Connected LOTO is worth exploring, but it must be implemented with care. Start with a pilot program before rolling it out facility wide. Involve IT early, since cybersecurity and connectivity are now part of the equation. Train workers not only on the digital steps, but also on the continued importance of physically applying the lock. 

Above all, treat connected lockout/tagout as an enhancement, not a replacement. The digital layer brings efficiency and visibility, but the physical lock remains the foundation of worker safety. 

This article originally appeared in the September 2025 issue of Occupational Health & Safety.