Page 41 - OHS, February/March 2025

L O C K O U T / T A G O U T
Advantages of Traditional Lockout/Tagout vs. Electronic
Advantages of Traditional Lockout/Tagout vs. Electronic
Lockout/Tagout Procedures
Lockout/Tagout Procedures
Th e pros and cons of traditional LOTO procedures versus modern electronic LOTO
systems, and how each method impacts safety, effi ciency, and standards compliance.
BY HERBERT POST
sin furniture factory in December 2020, he probably
When Wayne Rothering went to work at a large Wiscon-
thought he’d perform the same routines he did for a
while now and go home safe aft er a day at work. But
that was not the case. Rothering was performing maintenance on a
production line that glued laminating paper to fi berboard when he be-
came caught in the machinery’s adhesive rollers. Before the accident,
Rothering stopped the conveyor but did not dislodge it — a lockout
alternative that the company deemed enough to prevent accidents.
Th e devastating death of Wayne Rothering serves as a sobering
reminder of why lockout/tagout (LOTO) procedures are critical
for workplace safety. While some promote technological solutions
as an assurance of safety, others maintain that traditional LOTO
procedures remain essential. Th is article examines both traditional
lockout tagout procedures and modern electronic LOTO systems,
providing insights into how each approach impacts workplace
safety, operational effi ciency, and compliance with increasingly
stringent safety standards.
Traditional Lockout Tagout Procedures
Traditional lockout tagout procedures involve physically securing
energy isolation devices with locks and applying warning tags dur-
ing maintenance or servicing of equipment. Th is time-tested meth-
od requires workers to identify energy sources, notify aff ected em-
ployees, shut down equipment, isolate energy sources, apply locks
and tags, verify energy isolation, and perform necessary work before
systematically restoring energy through a clear removal procedure.
Below are the major advantages of traditional lockout tagout
procedures:
■ Physical Security and Visibility: Th e presence of physical
locks and tags provides clear visual confi rmation that equipment is
secured and who is responsible for the lockout, making it immedi-
ately apparent when machinery is under maintenance.
■ Independence from Technology: Traditional LOTO systems
continue to function regardless of power outages, soft ware glitch-
es, or system failures, ensuring safety measures remain intact even
when other systems are compromised.
■ Direct Worker Control: Workers maintain personal con-
trol over their safety through individual locks and tags, promoting
a sense of ownership and responsibility while ensuring equipment
cannot be reactivated until their lock is physically removed.
But this procedure, although time-tested, still has limitations:
■ Time-Intensive Implementation: Th e manual nature of tra-
ditional LOTO procedures requires signifi cant time for proper ex-
ecution, including physically walking to diff erent isolation points
KG/stock.adobe.com
and applying individual locks and tags.
■ Documentation Challenges: Paper-based tracking systems
can be cumbersome to maintain, making it diffi cult to ensure com-
pliance, track procedure history, and maintain up-to-date records of
LOTO activities.
■ Human Error Risk: Th e reliance on manual processes and
multiple steps increases the potential for procedural mistakes,
missed steps, or incomplete isolation of energy sources, particularly
in complex systems with multiple energy points.
Electronic Lockout Tagout Systems
Electronic lockout tagout systems use digital technology, soft ware
platforms, and automated controls to manage the isolation and
lockout of equipment. Th ese systems typically integrate with ex-
isting machinery through programmable logic controllers (PLCs)
and networked devices, allowing workers to initiate and monitor
LOTO procedures through digital interfaces, while still maintain-
ing physical lockout points for regulatory compliance.
Here are the major advantages of implementing electronic
LOTO systems:
■ Enhanced Tracking and Documentation: Electronic sys-
tems automatically generate detailed audit trails and documentation
of all LOTO activities, including timestamps, worker identifi cations,
and procedural steps completed, making compliance verifi cation
and incident investigation more effi cient.
■ Streamlined Workfl ow Management: Digital platforms
guide workers through step-by-step procedures with electronic
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