LOTO system in lighting production: how Trilux gained control over various energy sources and external companies

LOTO (Lockout Tagout) is a hazardous energy control system that protects employees during maintenance work on machines and installations. In this case study, you will learn how such an implementation — from audit, through equipment selection, to training and an educational video - enabled the TRILUX manufacturing plant to gain control over multiple energy sources, employees, and subcontractors from external companies.

See what a complete LOTO implementation looks like in practice and what benefits a plant actually gains by deciding to adopt it.

What challenges does the modern TRILUX plant face?

Trilux is a modern manufacturing plant specializing in lighting production, located in Świdnik near Lublin

Shift work, an extensive machine park, and an increasing number of external companies performing servicing and maintenance. The plant operates with several energy sources — electricity, compressed air (high and low pressure), and gas installations. Each of them poses a risk of dangerous energy release if a machine is not properly isolated before maintenance work. The more contractors on the plant premises, the harder it is to be sure that each of them knew the exact energy isolation procedure at a given workstation. The TRILUX team made it clear: the safety of employees and subcontractors — is a priority.

Solution: A LOTO system tailored to the plant

LOTO (Lockout Tagout) is a hazardous energy control system — in short! Contrary to common belief, it is not just about padlocks and lockout devices; real effectiveness is determined by precise instructions and trained people!

The 4safety team carried out the implementation comprehensively:

• an audit of the plant and all energy sources,
• selection of lockout equipment for specific machines and installations,
• detailed workstation instructions,
• a LOTO board with full equipment,
• initial and periodic training 
• an educational video for the quick onboarding of new employees and external companies.

See video coverage straight from the manufacturing plant! What does a LOTO implementation look like in practice and how did the cooperation proceed at every stage of the project? In the material, you will also hear statements from Adam Szymiec, Maintenance Manager, and Agnieszka Duda, EHS Manager for OHS/Environmental Protection.

The LOTO board also deserves special attention, as it was designed specifically for Trilux’s needs.

Each lockout device, padlock, and element has its exact place outlined in the shape of that element. The result? One glance is enough to see whether everything is in its place or whether someone is currently using a given lockout device on the shop floor. No counting, no checking a list — the missing element stands out on its own. For maintenance and OHS, this is a real convenience: the equipment is always complete, easy to inspect, and ready for use whenever a machine needs to be secured."