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Individual Project Presentation

Digital Lockout-Tagout

Digital Lockout-Tagout

A critical safety protocol that's been manual, paper-based and slow - relying on memory, handwritten logs and scattered approvals for the last 50 years.

One process, many stakeholders — No shared visibility

  • Operators

    physically lock the equipment — but without clear guidance, a missed step could put someone at risk.

  • Maintenance Teams

    can’t start repairs until they get approvals — any delay means downtime costs stacking up.

  • Safety Managers

    carry the weight of ensuring every lockout follows strict compliance protocols, because one failed audit could shut the whole facility down.

  • SCADA Operators

    keep the system running smoothly but had no way to see lock statuses in real time.

  • Facility Managers

    worry about efficiency and compliance across the board — but had to dig through paper logs to understand what’s happening.

  • Facility Managers

    worry about efficiency and compliance across the board — but had to dig through paper logs to understand what’s happening.

  • SCADA Operators

    keep the system running smoothly but had no way to see lock statuses in real time.

  • Safety Managers

    carry the weight of ensuring every lockout follows strict compliance protocols, because one failed audit could shut the whole facility down.

  • Maintenance Teams

    can’t start repairs until they get approvals — any delay means downtime costs stacking up.

  • Operators

    physically lock the equipment — but without clear guidance, a missed step could put someone at risk.

The system knew, the users didn’t.

This led to a critical safety risk - SCADA operators could unknowingly restart equipment, unaware technicians were still working on it.

Prototyping the process, not the interface.

From prototype to production…

Feedback from leaders

Don’t reinvent the lock — partner with IoT lock vendors who offer API access.

Don’t reinvent the lock — partner with IoT lock vendors who offer API access.

Skip the standalone app — integrate into an existing SE platform.

Skip the standalone app — integrate into an existing SE platform.

Clarify scope — narrow down the user group and environments where this would have most impact.

Clarify scope — narrow down the user group and environments where this would have most impact.

Narrowing down the scope through semi structured interviews & Kano surveys

Profiles interviewed

Operators

Safety Managers

Facility Managers

Kano Questionnaire Format

How would you feel if this feature was there?

How would you feel if it wasn’t?

Kano Model

Feature classifications

Must-be

Bare minimum, keeps users satisfied.

One-dimensional

The more you deliver, the happier they get.

Attractive

Unexpected but appreciated surprises.

Mapping userflow

Wireframes

First deployed prototype

Closing the loop — The outcomes

Cut down the LOTO process time by ~35%

Cut down the LOTO process time by ~35%

Operators could complete the workflow faster and with fewer errors.

Automated audit trails replaced manual paperwork

Automated audit trails replaced manual paperwork

Made compliance checks smoother and less prone to human error.

SCADA teams gained live visibility

SCADA teams gained live visibility

Reduced risk of accidental restarts, with real time updates of their systems.

Scalable across facilities and regions

Scalable across facilities and regions

Designed to adapt to different safety codes. Certification reviews in-progress globally.

Reflections

Building trust in high-stakes environments

Building trust in high-stakes environments

Balancing compliance and usability

Balancing compliance and usability

Navigating multiple stakeholders

Navigating multiple stakeholders

System thinking

System thinking

See more of my work

Other projects, other problems, same approach: make it useful, make it real.

Designing for real-world constraints — and real people.

Designed in Framer, copy perfected by Monday.

© 2025 Gaurav Sinha 🇮🇳

Designing for real-world constraints — and real people.

Designed in Framer, copy perfected by Monday.

© 2025 Gaurav Sinha 🇮🇳

Designing for real-world constraints — and real people.

Designed in Framer, copy perfected by Monday.

© 2025 Gaurav Sinha 🇮🇳