Lockout and Tagout in a Manufacturing Setting from a Situation Awareness Perspective

Applying lockouts during maintenance is intended to avoid accidental energy release, whereas tagging them out keeps employees aware of what is going on with the machine. In spite of regulations, serious accidents continue to occur due to lapses during lockout and tagout (LOTO) applications. Few studies have examined LOTO effectiveness from a user perspective. This article studies LOTO processes at a manufacturing organization from a situation awareness (SA) perspective. Technicians and machine operators were interviewed, a focus group discussion was conducted, and operators were observed. Qualitative content analysis revealed perceptual, comprehension and projection challenges associated with different phases of LOTO applications. The findings can help lockout/tagout device manufacturers and organizations that apply LOTO to achieve maximum protection.