Lockout Tagout elearning

Project Overview

The Challenge: Maintenance technicians and machine operators were exhibiting inconsistent safety compliance, reflected in low written-test scores and preventable workplace incidents. The legacy training was a passive "information-dump" that failed to prepare employees for the high-stakes decisions required on the plant floor.

The Goal: Increase safety compliance and assessment scores by transitioning from a passive knowledge model to a performance-based branching simulation.

Strategic Solutions

1. Action Mapping & Expert Collaboration

I collaborated closely with three Subject Matter Experts (SMEs) and frontline supervisors to analyze daily technician workflows. Using Action Mapping, I isolated the high-risk behaviors that led to previous safety incidents. This ensured the curriculum was stripped of non-essential theory and focused entirely on the critical steps of energy isolation.

2. Realistic Branching Simulations

Developed in Adobe Captivate, the course places learners in authentic maintenance scenarios.

• Non-Linear Paths: Learners choose their next steps in a simulated high-risk environment. Correct choices reinforce mastery, while incorrect choices lead to simulated "consequences," providing a safe-fail environment.

• Adaptive Difficulty: The branching logic allows experienced technicians to navigate familiar content quickly while identifying and closing specific knowledge gaps through job-based decision points.

  
  

3. Agile Design & Prototyping

To meet an aggressive sixteen-day timeline, I utilized an agile development process:

• Adobe XD Prototyping: Built an interactive storyboard to confirm the UI/UX and logic flow with stakeholders early in the process.

• LMS Integration: Delivered a fully SCORM-compliant module that integrated seamlessly with the organization’s existing Learning Management System.

  
  

Key Results & ROI

• Assessment Mastery: Facilitated a 22% increase in written-test scores, indicating significantly higher knowledge retention.

• Safety Impact: Lockout/Tagout-related incidents dropped by 12% in the months following implementation.

• Operational Buy-In: Received high approval ratings from both frontline employees and supervisors for the course’s realism and relevance to the "actual job."

  
  

Future Iterations: Performance Support

As a future enhancement, I plan to develop a mobile-accessible "Digital Job Aid" to complement the eLearning. This tool would allow technicians to scan a QR code at specific machinery to pull up a visual checklist of isolation points, bridging the gap between the classroom and the plant floor.

Skills Demonstrated

• Safety Compliance Training (OSHA Standards)

• Branching Scenarios & Decision-Based Learning

• Action Mapping & SME Interviewing

• Rapid Prototyping (Adobe XD & Captivate)