Lockout procedures are mainly used in factories or power plants to protect the workers who are working with large or dangerous machinery.
In its basic form, it serves as a form of communication between the workers who are fixing or servicing a machine to the workers using the machine.
The primary objective of Lock out - Tag out is to prevent the unexpected start-up of machinery and equipment or the unintentional release of stored energy that could severely injure or even kill employees during maintenance.
When a larger number of workers need to be locked out, of a machine a Group Lock Box would be used. In large power plants and factories, this is a common sight. Without, proper communication and paperwork confusion can arise.
Using a competitors group lock box and some role-playing we were able to get a better understanding of how the system works.
System Analysis of the Group Lockbox was done to discover specific user pain points that needed to be addressed.
A Snapshot of Brainstorm Sketching.
Key Concept Sketch
Key Concept Sketch
3-dimensional mockups to communicate ideas and discover problems.
Further Ideation in a specific concept.
In this mock-up, we realized some obvious problems that were not found by sketching. These problems need to be addressed before committing to the rounded concept.
The chosen concept, ready to be created in CAD and as a final prototype.
By using the curve, we were able to drastically improve the not only the number or boxes that fit on the wall but improve the over all lock capacity by almost 400 potentially removing the need for hasps and further confusion.
Brady lockbox Sizing
Wall Size
92 inches x 133 inches
75 - Brady lock boxes
75 - simultaneous jobs
525 - locks
525 - workers
Master Lock's
Lockbox Sizing
Wall Size
92 inches x 133 inches
84 Master Lock, lock boxes
84 - simultaneous jobs
924 - locks
924 - workers
Final hand built prototype
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Lockout - Tagout Group Lock Box
With the Master Lock group lock box provides ease of use with all the Elements to provide through attention to the situation at hand.
Each feature is thought out to provide for the user and clarify communication between the lead lock and the workers on the machine.
By taking away the small frustrations like bad ergonomics and adding more features that lessen confusion for regular consistent use of this safety box. It is strange to think that a box with holes can save a life.
