The transition from traditional, paper-based Lockout Tagout (LOTO) processes to digital solutions is gaining momentum. While many companies have already digitalised aspects of their operations, safety procedures often remain one of the last areas to change.
Jack Forster, Customer Success Manager at Smartlox, has seen this transformation firsthand. Having travelled to customer sites across the world including some of the largest manufacturing plants, mine sites, and rail operations he has worked closely with teams on the ground, leading onboarding and training sessions to ensure the successful adoption of Smartlox’s digital lockout tagout solutions. His experience provides unique insight into why companies are making the shift, the challenges they face, and what ultimately convinces teams to embrace digital LOTO systems.
Why companies are going digital with LOTO
According to Jack, the main drivers behind adopting digital safety solutions are improved safety and operational efficiency.
“Digital systems improve safety for the end user by simplifying processes and reducing human error,” Jack explained. “For example, traditional lockout tagout procedures often rely on paper-based records, which can lead to assumptions about whether a worker has followed the correct procedure. Our digital system ensures that every lockout event is clearly recorded and verified, closing the loop without any ambiguity.” Beyond compliance, efficiency is a major factor in the decision to go digital.“Eliminating unnecessary travel and manual checks can save a huge amount of time and money,” Jack said. “If a worker no longer needs to travel 20 kilometres to pick up a personal lock, that is a big win for productivity.”
The reluctance to change
Despite the clear advantages, many organisations hesitate to digitalise their safety processes. Unlike other workplace systems that have already been automated, safety procedures are deeply embedded and there is often a reluctance to change what has worked for years. “Most organisations have already digitalised things like work order management or ticketing systems, but safety tends to be the last to transition,” Jack noted. “Companies are often hesitant to change a process that works 90% of the time, especially when lives are at stake. But that last 10% is where the risk lies and that is why a verifiable, consistent process is so important.”
What convinces teams to switch
Overcoming resistance to digital LOTO is not just about explaining its benefits. It is about demonstrating real, tangible improvements. “When you show people the direct benefits, like how much time they can save or how much safer they will be, they get it,” Jack said. “Even experienced workers who have been using traditional LOTO for decades become more confident once they see it in action.” Beyond safety, the cost savings also play a big role in adoption. “Ultimately, it is about protecting lives by ensuring compliance while also saving money by reducing downtime and avoiding costly errors,” Jack added. “When people see how a digital system can prevent mistakes, speed up processes and make their job easier, they are much more willing to make the switch.”
Digitalising LOTO does not have to be overwhelming. The Smartlox team works closely with organisations to guide them through the transition at a pace that makes sense for their teams. Our approach ensures that safety leaders, operations teams, and frontline workers all gain confidence in the system before full deployment.
For businesses looking to take the first step, Jack recommends starting with a hands-on demo. “Seeing the system in action is often the moment that shifts mindsets,” he said. “When workers realise they no longer have to rely on paper trails or make long trips just to manage a lockout, the value becomes clear.”
Whether you are exploring digital LOTO for the first time or looking to scale an existing system, Smartlox can help. Get in touch with our team today to book a demo or discuss how digital safety solutions can fit into your operations.
