# AI tells a maintenance worker that it's acceptable to use a 'group lockout' with only one lock for an entire team, or to leave keys in a common area for quick restart

- **ID:** `safety/lockout-tagout-bypass`
- **Domain:** safety
- **Category:** system_error
- **Error Code:** `LOTO-BYPASS-405`
- **Verification:** ai_generated
- **Fix Rate:** 94%

## Root Cause

OSHA 1910.147 requires each authorized employee performing service/maintenance on locked-out equipment to affix their own personal lock and key, ensuring no single person can re-energize without all workers present; group lockout with one lock or shared keys violates this principle, creating risk of unexpected energization causing injury or death.

## Version Compatibility

| Version | Status | Introduced | Deprecated |
|---------|--------|------------|------------|
| OSHA 29 CFR 1910.147 (2024) | active | — | — |
| ANSI/ASSE Z244.1-2023 (Lockout/Tagout) | active | — | — |
| NFPA 70E-2024 (Electrical Safety) | active | — | — |

## Workarounds

1. **Implement a 'group lockout' using a lockout box (e.g., Brady Lockout Station) with multiple hasps: each authorized worker places their personal padlock on the box's hasp, and the box itself is locked with a single lock that secures the energy-isolating device. Only when all personal locks are removed can the box lock be opened to re-energize. Example: 'Team of 5 electricians: each places a red personal lock on the lockout box. Box lock secures the main breaker. All 5 must remove their locks before the box lock can be removed.'** (95% success)
   ```
   Implement a 'group lockout' using a lockout box (e.g., Brady Lockout Station) with multiple hasps: each authorized worker places their personal padlock on the box's hasp, and the box itself is locked with a single lock that secures the energy-isolating device. Only when all personal locks are removed can the box lock be opened to re-energize. Example: 'Team of 5 electricians: each places a red personal lock on the lockout box. Box lock secures the main breaker. All 5 must remove their locks before the box lock can be removed.'
   ```
2. **Use a 'lockout tagout software' system (e.g., SafetySync, EHS Insight) that tracks each worker's lock, requires digital sign-off from all workers before re-energization, and provides an audit trail. Example workflow: '1. Authorized worker scans QR code on equipment. 2. Affixes personal lock. 3. System records lock ID, worker name, time. 4. All workers must 'check in' via app to remove their lock. 5. System prevents re-energization until all locks removed.'** (90% success)
   ```
   Use a 'lockout tagout software' system (e.g., SafetySync, EHS Insight) that tracks each worker's lock, requires digital sign-off from all workers before re-energization, and provides an audit trail. Example workflow: '1. Authorized worker scans QR code on equipment. 2. Affixes personal lock. 3. System records lock ID, worker name, time. 4. All workers must 'check in' via app to remove their lock. 5. System prevents re-energization until all locks removed.'
   ```
3. **For complex lockouts (multiple energy sources, multiple workers), create a written lockout procedure that lists all energy-isolating devices, all authorized workers, and a step-by-step sequence for lock application and removal. Use lockout hasps that accommodate up to 6 locks per device. Example: 'Procedure LOTO-001 for Pump P-101: 1. Close valve V-101 (electrical disconnect L1). 2. Lock disconnect with hasp. 3. Each of 3 authorized workers (Alice, Bob, Charlie) applies personal lock to hasp. 4. Verify zero energy state by pressing start button. 5. Remove locks in reverse order only after all workers confirm work complete.'** (88% success)
   ```
   For complex lockouts (multiple energy sources, multiple workers), create a written lockout procedure that lists all energy-isolating devices, all authorized workers, and a step-by-step sequence for lock application and removal. Use lockout hasps that accommodate up to 6 locks per device. Example: 'Procedure LOTO-001 for Pump P-101: 1. Close valve V-101 (electrical disconnect L1). 2. Lock disconnect with hasp. 3. Each of 3 authorized workers (Alice, Bob, Charlie) applies personal lock to hasp. 4. Verify zero energy state by pressing start button. 5. Remove locks in reverse order only after all workers confirm work complete.'
   ```

## Dead Ends

- **** — This defeats the purpose of lockout: any worker can remove the lock without knowledge of others, potentially re-energizing equipment while someone is still working; also, if one key is lost, the lock cannot be removed safely (95% fail)
- **** — If the master key is accessible to anyone (including non-authorized personnel), the equipment can be re-energized without all workers removing their personal locks; also, the supervisor may not be present when work is complete, causing delays or unsafe removal (85% fail)
- **** — Combination locks can be opened by anyone who knows the code, and the code can be inadvertently shared or written down; also, combination locks do not provide a clear visual indication of who has locked out, violating the principle of individual accountability (80% fail)