Why the LOTO system works in reducing accidents
We discussed what LOTO is and how it works in a previous article.
If you feel like it, watch this illustrative video for easy understanding.
Article LOTO basics
When working with electrical installations, electricians must follow strict regulations and standards, including safeguards against starting. Yet, electric shocks are a common cause. Why?
Accident rate USA
Fatallity per 100 000 worked hours | |
average | 0,10 |
electrician | 2,75 |
Almost 30 times higher probability of fatal injury!
(68-80 cases per year, 1/3 of which are due to electric shock)
Approximately 25 unnecessary deaths per year.
Do you know how many fatal work accidents there were in Slovakia related to electricity and what proportion is it?
It is 1 fatality = 4%.
Safety in a machine and equipment environment is a key element of any business that uses machines. One of the most effective methods of preventing accidents during machine maintenance and service is the Lockout/Tagout (LOTO) system – i.e. locking and tagging energy sources so that the equipment cannot be started unexpectedly. The results of several scientific studies confirm that a properly implemented LOTO system significantly reduces the number of work-related accidents, improves employee safety behavior and strengthens the safety culture.
Proven benefit in practice
According to a study by Hanafi & Sholihah (2017) from Andalas University in Indonesia, a significant reduction in injury rates was demonstrated after the implementation of the LOTO system in a group of heavy machinery mechanics. The research looked at the differences before and after the implementation of the LOTO procedure and found a statistically significant reduction in injuries caused by crushing, falling, crushing and impact. The authors concluded that LOTO is an effective risk control tool, as it eliminates dangerous unexpected movements of machinery during maintenance.
Similarly, the National Machine Guarding Program in Small Businesses (National Machine Guarding Program, 2016) published in the Journal of Occupational and Environmental Hygiene showed that small manufacturing companies that implemented LOTO and established internal audits of its compliance experienced a 30% reduction in incidents compared to the control group. The program confirmed that even in small businesses, systematic energy lockout has a measurable effect on safety.
Reasons for LOTO’s Success
The effectiveness of the LOTO system lies in the fact that it eliminates the very cause of accidents – the uncontrolled release of energy. While traditional training often only appeals to the employee’s attention, LOTO creates a physical barrier between the person and the dangerous source. According to Kumar & Tauseef (2018), who analyzed different types of LOTO devices, the correct choice of locking mechanism and clear marking of the energy source are key to minimizing the risk of different types of dangerous energies – electrical, hydraulic, pneumatic or mechanical.
A study by Ihalainen et al. (2019) published in the journal Safety warns that the success of LOTO does not depend only on technical equipment, but also on “situational awareness” – the awareness of workers about what is happening. The authors found that errors in the perception and understanding of the LOTO procedure lead to misunderstandings that can cause the failure of the entire system. Therefore, it is important that LOTO training is not just formal, but that it develops the ability of workers to anticipate risks.
The importance of proper implementation
On the contrary, Dewi’s (2018) analysis points to cases of LOTO procedure failures that arose due to communication errors, insufficient control or supervisor negligence. This confirms that LOTO only works when it is consistently implemented and regularly audited. The author recommends the introduction of systematic control, where each step of locking, tagging and releasing energy must be documented and verified by a responsible person.
LOTO as part of a safety culture
In addition to the technical aspect, LOTO also has a psychological effect. When employees know that the company places emphasis on physical risk control and their personal safety, their confidence and motivation to follow the rules increase. Case study Mohammad et al. (2023) from a Malaysian company showed that the development of a “LOTO Quality Manual” helped not only reduce the number of incidents but also improve the perception of safety among workers.
Conclusion
The Lockout/Tagout system is a proven, science-based approach to preventing workplace injuries. Its strength lies in its simplicity, systematic nature, and the fact that it combines technical, organizational, and behavioral safety elements. Studies from various industries show that when implemented consistently – with an emphasis on training, control, and accountability – LOTO leads to measurable reductions in injury rates and reinforces a culture of safe work.
