Transforming Lock Out Tag Out Flag Storage with Custom Foam and Pelican Case Design

Background

Our client initially used a wooden paddle design to store and manage their Lock Out Tag Out (LOTO) flags. While functional, this solution was bulky, time-consuming to use, and lacked the safety and efficiency necessary for modern operations.

Challenge

The original wooden paddle system posed several challenges:

  • Space Inefficiency: The bulky design occupied unnecessary space, making storage and transport cumbersome.
  • Time Consumption: Workers spent extra time handling the paddles, impacting overall productivity. At a glance, it’s nearly impossible to identify missing flags causing workers to individually count or rummage through intertwined wires to identify missing pieces.
  • Safety Concerns: The wooden paddles were susceptible to wear and tear, raising potential safety issues over time, and didn’t provide the proper protection for the flags.

Solution

We collaborated closely with the client to understand their specific needs and challenges. After careful analysis, we transformed the wooden paddle design into a sleek, custom foam and case solution housed inside a durable Pelican 1650 case. This new design offered several key benefits:

  • Cost Savings: The compact and organized foam design reduced the overall size of the storage system, leading to cost savings in both storage and transportation. The durability of the Pelican case also minimized replacement costs, ensuring long-term savings.
  • Time Efficiency: The custom foam insert provided quick and easy access to each LOTO flag, drastically reducing the time needed for setup and deployment. This streamlined process allowed workers to focus on their tasks without unnecessary delays.
  • Enhanced Safety: The precision-cut foam securely held each flag in place, reducing the risk of damage and ensuring that the flags were always in optimal condition. The rugged Pelican case further protected the contents from environmental factors, enhancing overall workplace safety.

Outcome

Our custom foam and Pelican case design transformed the client’s LOTO flag management system. The new solution not only improved efficiency and safety but also delivered significant cost savings. By transitioning from a wooden paddle to a sleek, modern case, the client now enjoys a more reliable, efficient, and cost-effective system for managing their LOTO flags.