Lockout / Tagout as a Practical Tool for the Vision Zero Concept

Lockout/Tagout as the Foundation of Safe Equipment Maintenance

Implementing a Lockout/Tagout (LOTO) system is not just about following international standards, but a fundamental step towards realizing the Vision Zero concept. Historically established methods of equipment lockout, such as using ordinary chains and locks, left room for human error. The modern LOTO approach eliminates the accidental supply of energy to the workplace by transferring control directly to the workers. During the webinar, experts Ruslan Lazarev (AkzoNobel) and Maxim Miroshnichenko (Enel Russia) share their practical experience in transitioning from formal procedures to a reliable hazardous energy lockout system.

Implementation Stages: From Risk Assessment to Automation

Ruslan Lazarev emphasizes that successful LOTO implementation begins with an in-depth risk assessment. At the first stage, it is critical to identify the equipment and lockout points. At AkzoNobel, this process included an internal audit and the involvement of third-party experts to confirm the correctness of the chosen solutions, especially for non-standard equipment. The development of internal procedures that take into account both corporate and international requirements became the basis for the subsequent purchase of lockout devices, padlocks, and LOTO boxes.

Maxim Miroshnichenko, representing PJSC Enel Russia, demonstrates how the LOTO system is integrated into existing business processes. At the company's power plants, the permit-to-work issuance process is automated through the SAP system. Technical assistants generate orders, which are then transformed into permits-to-work with detailed safety measures. Every lockout action is confirmed by the signature of the responsible person, ensuring transparency and strict control at every stage.

Overcoming Resistance and Personnel Adaptation

One of the main challenges in implementing LOTO, as Ruslan Lazarev notes, is changing the mindset of employees. At the beginning of the journey, operators and maintenance personnel often did not understand the need for new, seemingly redundant procedures. The solution was regular training and the simplification of routine tasks: creating lists of equipment to be disconnected for standard work and document templates. This significantly reduced the time spent on organizational activities and lowered personnel resistance.

Practical Nuances: Video Permits and Group Lockboxes

The speaker analyzes the specifics of working at complex facilities where mechanics do not have access to electrical rooms. Enel Russia has introduced the practice of video permits: the on-duty electrician records the process of taking the equipment out of service on video, which is then shown to the maintenance personnel. This guarantees that the equipment is indeed de-energized and locked out.

Special attention is paid to the use of group LOTO boxes. Keys from locked energy sources are placed in a box, on which each participant in the work (from the technical assistant to the direct executor) hangs their individual lock. Until all locks are removed, the supply of energy is impossible. The speaker shows by example how the color grading of locks helps to visually identify the roles of the process participants.

What you will learn from this webinar:

• How to properly conduct a risk assessment and identify equipment lockout points?
• How to integrate LOTO procedures into an existing permit-to-work system (including via SAP)?
• How to overcome personnel resistance when implementing new safety standards?
• How to organize safe access for mechanics to work requiring power outages using video recording?
• What to do in emergency situations, for example, if an employee forgot to remove their individual lock after the end of the shift?