Page 30 - OHS, November/December 2024

L O C K O U T / T A G O U T
Connected Lockout/Tagout
LOTO is critical and complex, but businesses have new technology solutions to ensure
compliance and safety. What’s involved?
BY DAVID KOPF
critical to safeguarding workers from hazardous energy dur-
Lockout/Tagout (LOTO) is an essential set of procedures are
ing maintenance and servicing activities.
OSHA mandates the use of LOTO practices to prevent
the unexpected startup or release of stored energy that can result
in severe injuries or fatalities. According to OSHA’s standards (29
CFR 1910.147), LOTO procedures must be implemented when-
ever workers are exposed to machinery or equipment that could
unexpectedly energize, start up, or release hazardous energy, put-
ting them at risk of serious harm.
LOTO protects workers by ensuring that machinery or equip-
ment remains fully de-energized and secured during maintenance
or servicing. Th is process prevents accidental startup and controls
various types of hazardous energy sources, including electrical,
hydraulic, pneumatic, mechanical, and thermal energy. Without
LOTO, workers are vulnerable to severe injuries, such as electro-
cution, crushing, burns, and amputations.
In OSHA-compliant LOTO, equipment must be shut off and
disconnected from its energy sources before any work is per-
formed. Employees must apply locks and tags to control these en-
ergy sources and verify the isolation before beginning work. Also,
only authorized personnel are permitted to remove locks, ensuring
that only trained individuals can manage hazardous energy safely.
Technology Solutions
However, LOTO methods rely on physical locks, tags, and manual
documentation, which, while eff ective, can lead to ineffi ciencies and
potential errors, especially in large-scale or high-risk operations.
Ensuring compliance can get particularly knotty in large facilities
or operations with intricate machinery and multiple energy sources.
Not surprisingly, companies recognize the need to modernize
their LOTO processes can streamline safety procedures, improve
effi ciency, and reduce the risk of accidents, making innovative ap-
proaches a valuable asset in today’s demanding safety landscape.
So, digital solutions have emerged to help facilitate streamlined,
accountable, and data-driven safety practices. By integrating digi-
tal tools, such as mobile applications, real-time dashboards, and
tamper-resistant locks, companies can create safer environments
and simplify compliance with regulatory requirements.
Th e latest innovation: Connected LOTO. Connected LOTO
systems incorporate a combination of Internet of Th ings (IoT)
devices, mobile applications, cloud platforms, and real-time data
analytics to enhance safety and effi ciency. Some key elements of
connected LOTO:
■ IoT-enabled locks and sensors form the core of these sys-
tems, providing real-time monitoring of lockout points and re-
porting status updates, which can help prevent unauthorized ac-
cess or accidental re-energization.
■ Mobile apps empower workers to access LOTO procedures,
track lockouts, and verify equipment status from anywhere, mak-
ing it easier to follow protocols in complex or multi-site facilities.
■ Cloud-based platforms centralize LOTO data, enabling re-
mote management, digital record-keeping, and streamlined com-
pliance reporting.
■ Real-time analytics off er insights into LOTO patterns, al-
lowing companies to proactively address recurring issues and opti-
mize safety practices.
Connected LOTO
Together, these technologies enable a comprehensive, connected
approach to LOTO that traditional methods alone cannot achieve.
Some example scenarios:
■ In a manufacturing facility, connected LOTO allows tech-
nicians to lock out electrical panels on high-voltage equipment
remotely, ensuring real-time monitoring and alerts to prevent ac-
cidental re-energization.
■ At a chemical processing plant, maintenance teams use con-
nected LOTO to coordinate lockouts across multiple shift s, ac-
cessing real-time status updates to verify that all hazardous energy
sources remain securely isolated during repairs.
■ In a large distribution warehouse, connected LOTO enables
supervisors to oversee the lockout of conveyor systems from a
central dashboard, providing immediate visibility into each lock’s
status and ensuring compliance across a fast-paced, multi-worker
environment.
For companies interested in exploring connected Lockout/Ta-
gout (LOTO) solutions, a good fi rst step is to conduct a needs as-
sessment of their current LOTO procedures to identify gaps where
technology could improve safety, compliance, and effi ciency.
Several prominent vendors off er connected Lockout/Tagout
(LOTO) products that incorporate digital and IoT capabilities to en-
hance safety and compliance. Master Lock provides the cLOTO solu-
tion, a system that enables real-time monitoring and control of lockout
points via an integrated app and digital lock components, designed
to streamline LOTO for complex facilities. Brady Corporation off ers
comprehensive LOTO devices and services, including its LINK360
soft ware, which centralizes procedure management and allows com-
panies to update and verify lockout procedures digitally. Another key
player, SEAM Group (recently acquired by ABB), provides digital
LOTO solutions that use QR code scanning for easy access to lockout
information, ensuring real-time oversight of all lockout points. For
more specialized applications, Rockwell Automation supports indus-
trial facilities with a range of customized LOTO device recommenda-
tions and program management tools, assisting companies in meeting
safety standards through tailored, connected solutions. Products like
these refl ect the diverse capabilities and applications that connected
LOTO systems bring to modern safety management.
David Kopf is the Publisher and Executive Editor of Occupational
Health & Safety.
30 Occupational Health & Safety | NOVEMBER/DECEMBER 2024 www.ohsonline.com