AI-Powered Safety Monitoring & SIF Prevention in Manufacturing
Manual shop-floor safety checks can miss critical hazards, leading to serious injuries and costly incidents. For a leading manufacturing client, we deployed an advanced AI-powered safety monitoring platform that continuously monitors worker activity, detects real-time risks, and proactively prevents Serious Injury and Fatality (SIF) events – before they happen.
Key Features
Real-Time PPE & Hazard Detection
We trained custom vision models to run on edge appliances at 30+ fps, spotting missing or improperly worn hard hats, gloves, vests, goggles. Supervisors get immediate mobile and on-site alerts for non-compliance, helping prevent accidents and keep everyone safer.
Sensor Fusion & Proximity Alerts
By combining data from Bluetooth/RFID badges, wearable sensors, and video feeds, our system creates smart zones around equipment. If someone gets too close to moving machinery, they receive instant haptic and visual alerts—helping prevent near-misses before they happen.
Ergonomic Risk Monitoring
Our solution analyzes workers’ movements in real time, flagging unsafe lifting or awkward postures. Instant coaching cues help prevent strains and injuries before they happen.
Predictive Risk Analytics & Hotspot Scoring
Our machine-learning models analyze past incidents, shift patterns, weather, and near-miss logs to generate dynamic risk heatmaps. Safety managers use these “hotspot” scores to deploy targeted patrols and training proactively.
Automated Compliance Dashboard
All alerts, video snippets, and sensor logs stream into a secure cloud dashboard. Custom reports on incident rates, PPE compliance, and training needs are generated automatically; eliminating manual logbooks and streamlining regulatory audits.
Benefits
By catching nearly all unsafe conditions before they could escalate, our client saw a dramatic year-over-year drop in serious incidents.
Continuous, automated monitoring drove glove, hard-hat, and vest usage from 70% to 98% within just three months.
Avoided incident costs, insurance-premium discounts, and productivity gains delivered more than three-times the safety investment back to our client.
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