Dubai Power Generation Manufacturer Boosts Safety with viAct Forklift Safety System during Facility Relocation
A global manufacturing leader in Dubai, specializing in power solutions and energy equipment, was relocating and consolidating multiple operations into a new facility. The transition raised critical safety challenges around heavy equipment handling, forklift movements, and PPE compliance across the upgraded workspace. Traditional manual supervision proved insufficient to track and prevent violations in real time. To strengthen safety, the company deployed viAct AI-powered monitoring modules to ensure seamless compliance during and after the move.
88% fewer PPE Violations
by detecting helmets and safety shoes across assembly lines.
65% Safer Forklift Operations
by preventing pedestrian collisions inside the new facility.
40% Faster Safety Audits
with documentation of violations on the dashboard, ensuring accountability
Company Overview
This Dubai-based manufacturing giant is a key player in energy solutions, producing diesel generators, solar-powered systems, and engineered equipment. With 8,000+ employees, the company recently consolidated operations into a new advanced facility. The relocation created an opportunity to strengthen safety culture. Dedicated to efficiency, compliance, and innovation, the firm invested in AI-powered monitoring to ensure safe, streamlined assembly operations across the new site.
Story Snapshot
During relocation, risks from forklift movement, PPE non-compliance, and manual inspections threatened productivity. To prevent safety gaps, the manufacturer deployed viAct AI video analytics. The deployment enabled a 54% decline in safety violations, reduced response time to by 71%, and streamlined safety reporting, making facility audits more reliable and significantly enhancing worker confidence in upgraded site.
Industry:
Energy
Location:
Dubai
Use Case:
Forklift & PPE
The Challenge
Ensuring safety compliance during facility relocation and consolidation
When this Dubai-based manufacturing leader consolidated multiple units into a new advanced facility, safety challenges multiplied. Forklifts were navigating unfamiliar layouts, workers were adjusting to redesigned assembly zones, and supervisors struggled to enforce PPE compliance amid the transition. Reliance on periodic audits and manual oversight meant hazards could go unnoticed until accidents or stoppages occurred. With relocation timelines already tight, the risk of delays, injuries, and compliance breaches grew significantly. Leaders needed a future-ready solution to provide real-time visibility across operations and eliminate safety blind spots during the high-pressure move.
For leadership, the relocation was more than just moving equipment; it was about building trust in a safer, smarter workplace. A digital-first safety framework was the only way to turn the new facility into a benchmark for compliance and operational efficiency.
“Relocation brought new layouts, heavy equipment traffic, and rising risks. Manual checks couldn’t keep up. viAct gave us visibility and assurance, turning a difficult transition into a safer, smoother success.”
Operations Director
Dubai Power Generation Manufacturer
The Solution
Turning Data into Accountability During Relocation
To maintain accountability during the high-pressure relocation, all safety violations and alerts were captured in a unified dashboard, providing supervisors with real-time documentation and actionable insights. This ensured that no incident went untracked, turning traditional manual oversight into a proactive, always-on system. On top of this, AI video analytics monitored helmet and safety shoe compliance across assembly lines, while forklift movements were tracked to prevent pedestrian collisions, ensuring the new facility remained safe and compliant despite unfamiliar layouts and heavy equipment traffic.
“viAct’s dashboard gave us instant visibility into all safety incidents, making accountability clear and actionable throughout the relocation,” said the Operations Director, Dubai Manufacturing Giant.
“The AI modules for PPE and forklift monitoring allowed us to proactively prevent accidents and enforce compliance without disrupting operations,” added the Safety Manager.
Helmets & Safety Shoes Detection Across Assembly Lines
During the relocation, the company faced significant challenges enforcing PPE compliance across newly designed assembly zones. To tackle this, viAct deployed AI video analytics to automatically detect helmets and safety shoes in real time across all assembly lines. The system continuously monitored workers, identifying violations instantly and sending alerts to supervisors, ensuring adherence even amid unfamiliar layouts. By automating PPE checks, the company minimized human error, reduced risk exposure, and maintained operational continuity during the move, turning a fragmented safety approach into a proactive, always-on compliance framework.
Forklift Safety System to Prevent Pedestrian Collisions
Relocation introduced unfamiliar layouts, increasing the risk of forklift and pedestrian collisions. To address this, viAct implemented an AI-powered forklift safety system that tracked forklift movements and pedestrian presence simultaneously. The system generated instant alerts to operators and supervisors, preventing potential accidents before they could occur. By providing continuous monitoring, the module improved operator awareness, ensured safe navigation around crowded zones, and reduced the likelihood of injuries during high-traffic periods. This proactive solution transformed forklift operations, making them safer, more efficient, and aligned with strict compliance standards in the new facility.
The Impact
Digital-First Safety Management for Relocation Success
The true value of viAct extends beyond immediate compliance during the facility relocation. Over time, the AI-driven system created a continuous safety record, documenting violations, incidents, and near-misses to build a reliable data trail.
This living record supports regulatory reporting, internal audits, and operational reviews. By demonstrating measurable improvements in PPE compliance and forklift safety, the company strengthened its credibility with clients and partners.
Real-time alerts also fostered a culture of proactive safety, enhancing workforce trust, engagement, and retention while reducing operational risks and potential downtime.
“viAct transformed safety into a strategic advantage, giving us measurable insights, fostering workforce trust with operational resilience.”
Operations Director
Dubai Power Generation Manufacturer