Lockout/Tagout (LOTO) Electrical Software Documentation

Overview

Purpose

A complete solution designed to automate, enforce and manage the Lockout/Tagout (LOTO) safety procedures for electrical equipment and machinery in hazardous areas. Software complies with OSHA standards and would help prevent injuries and/or accidents during machinery maintenance by locking out all machines in an “OFF” state position before maintenance tasks as performed.

The system handles multiple users, including roles viz. technicians and administrators, to streamline the management of machinery, lockout procedures, and permits/records while offering real-time tracking and alerting functionalities.

Scope

It covers functional requirements, architecture, components and workflows of the LOTO Electrical software. Information about the system to meet the safety compliance and operational efficiency goals for businesses.

Key features

User Management

  1. Admins can manage/assign roles viz. technicians, engineers or approvers and configure permissions
  2. Role based access control

Machinery Management

  1. Track all machinery and electrical equipment within the defined zone
  2. Track and secure status, power sources and isolation points for each component

LOTO Procedures

  1. Lockout/Tagout procedures for each operation
  2. Historical records and trends for audit and future compliance checks

Alerts and Notifications

  1. Auto notification for incomplete or pending locks
  2. Auto alerts to responsible personnel for time saving actions

Compliance and Analytics

  1. Following OSHA regulations
  2. Reports for audits, reviews, and internal assessments

Real-Time monitoring

  1. Status of machinery and operations in real-time
  2. Visual dashboards for simultaneous viewing

System Architecture

High Level Architecture

The architecture follows a 3-tier structure for ensuring security, scalability and maintenance. The components are:
  1. Presentation Layer (Front-end): Provide UI for admins and technicians, built with accessibility for mobile based browser
  2. Application Layer (Business Logic): Manage business rules, actions and workflows, LOTO procedures and notifications
  3. Data Later (Back-end): Stores user, machinery, records data

Technology Stack 

  1. Front-end: ReactJS or AngularJS for UI, HTML5/CSS3 for styling
  2. Back-end: Java or Python or NodeJS based services using RESTful APIs
  3. Database: PostgreSQL or MySQL for relational data management
  4. Notifications: Integration with email or SMS services for alerts.

Security Considerations

  1. User Authentication and Authorization: Secure login with multi-factor authentication (MFA), role-based access control
  2. Audit Logs: Detailed logs of all user actions for auditing and compliance checks
State Diagram - LOTO
State Diagram - LOTO



Functional components

Class Diagram LOTO
Class Diagram - LOTO


User Management

  • Description: Handles user roles, access permissions, and organisational hierarchies
  • Actors:
    • Admins – Responsible for creating and managing user accounts, roles, and permissions.
    • Technicians – Users who perform LOTO operations on Machinery

Machinery Management

  • Description: Centralized repository for tracking all machinery
  • Actors:
    • Admins – Manage and configure Machinery
    • Technicians – View and apply LOTO procedures to machinery

LOTO Procedure Management

  • Description: Manage lockout procedures/tagging
  • Actors:
    • Admins – define and maintain the procedures
    • Technicians - Perform LOTO procedures according to predefined steps

Record and Permit Management

  • Description: Tracks and Logs for auditing
  • Actors:
    • Admins – Generate reports and view historical data, trends
    • Technicians – Create records during performing the actions

Notification and Alert System

  • Description: Auto alerts for pending and required actions
  • Actors:
    • Admins/Technicians – Receive notifications for each task

User Roles and Responsibilities

Admin

  • Role: Manages the user permissions, equipment configurations
  • Responsibilities
    • Create and assign roles
    • Manage LOTO procedures
    • Configure notification and monitor system’s health

Technician

  • Role: Perform LOTO operations on machinery
  • Responsibilities
    • Follow all defined procedures
    • Verify isolation and record the data
    • Monitor machinery status and check compliance

System Workflow

Activity Diagram - LOTO
Activity Diagram - LOTO

Sequence Diagram - LOTO
Sequence Diagram - LOTO



Lockout/Tagout Operation

  • Identify Equipment: Technician selects the machine form the list
  • Isolate the Power source: Technician isolates the power source as per the guidelines
  • Lock and Tag: Appy physical lock and tags to the machine
  • Verify Isolation: To verify that power source is off
  • Maintenance: to carry out periodic maintenance/repair
  • Remove Lock and Tag: After maintenance, removal of locks and tags

Alert Flow

  • Trigger: any event triggers an alert (for example pending request)
  • Notification: System sends email/SMS notification to the responsible user
  • Action: User logs in to resolve any conflict

Reporting and Compliance

  • Audit Reports: Generate analytics and LOTO operations reports. 
  • Real Time Dashboard: A high-level view of the status of the circuitry
  • Compliance Checks: Ensuring system meets the OSHA regulations

Future Enhancements

  • IoT Integration for Automation
  • AI-based Risk Assessment

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