Advantages of Traditional Lockout/Tagout vs. Electronic Lockout ...

Advantages of Traditional Lockout/Tagout vs. Electronic Lockout/Tagout Procedures

The pros and cons of traditional LOTO procedures versus modern electronic LOTO systems, and how each method impacts safety, efficiency, and standards compliance.

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When Wayne Rothering went to work at a large Wisconsin furniture factory in December , he probably thought he’d perform the same routines he did for a while now and go home safe after a day at work. But that was not the case. Rothering was performing maintenance on a production line that glued laminating paper to fiberboard when he became 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.

The 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. This article examines both traditional lockout tagout procedures and modern electronic LOTO systems, providing insights into how each approach impacts workplace safety, operational efficiency, and compliance with increasingly stringent safety standards.

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Traditional Lockout Tagout Procedures

Traditional lockout tagout procedures involve physically securing energy isolation devices with locks and applying warning tags during maintenance or servicing of equipment. This time-tested method requires workers to identify energy sources, notify affected employees, 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:

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1. Physical Security and Visibility: The presence of physical locks and tags provides clear visual confirmation that equipment is secured and who is responsible for the lockout, making it immediately apparent when machinery is under maintenance.
2. Independence from Technology: Traditional LOTO systems continue to function regardless of power outages, software glitches, or system failures, ensuring safety measures remain intact even when other systems are compromised.
3. Direct Worker Control: Workers maintain personal control 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.