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Guardians of the Factory Floor: 5 Ways Manufacturers Can Use AI Video Analytics for Workplace Safety

AI Video Analytics for Workplace Safety
Guardians of the Factory Floor: 5 Ways Manufacturers Can Use AI Video Analytics for Workplace Safety

In the dynamic landscape of manufacturing, safety stands as a pivotal concern. The manufacturing industry contends with multifaceted safety risks that endanger workers and disrupt operations. According to a report by the International Labour Organization (ILO), Asia accounts for approximately 60% of all fatal occupational accidents worldwide, with a substantial portion occurring within the manufacturing sector. Factors such as rapid industrialization, inadequate safety regulations, insufficient training, and often outdated equipment contribute to these alarming statistics.


Out of various safety issues in factory floors, the following forebears are alarming and account for significant portion of incidents:

  • Machinery-related accidents resulting from improper usage, maintenance gaps, or equipment malfunctions

  • Hazardous materials handling leading to chemical exposure or fires if mishandled or stored incorrectly

  • Musculoskeletal disorders related to workplace ergonomics associated with repetitive tasks or poor workstation design

  • Insufficient training, fatigue, and compounding human errors during Simultaneous Operations (SIMOPS)


Thus, emphasizing on the urgent need for enhanced safety measures, technological advancements like AI-driven solutions are essential to mitigate these risks. AI video analytics is the ultimate solution for manufactures to improve safety protocols within various manufacturing units by providing real-time monitoring and analysis, significantly reducing workplace accidents and enhancing productivity.

5 Ways Manufacturers Can Use AI Video Analytics for Workplace Safety
5 Ways Manufacturers Can Use AI Video Analytics for Workplace Safety

Here are how manufacturers can enhance manufacturing safety using AI Video Analytics:

1. AI Video Analytics for Workplace Safety for Forklift Safety in Beverage Manufacturing Industry

In the manufacturing industry like beverage industries, forklifts play a crucial role but also pose significant safety risks. AI Video Analytics for beverage manufacturing industry has emerged as a game-changer in enhancing forklift safety within these environments. By employing AI-driven systems, cameras strategically placed across floors of beverage manufacturing units can continuously monitor forklift movements and behaviors in real-time. These systems are designed to detect potential safety breaches, such as reckless driving, unauthorized personnel near forklift zones, or imminent collisions with objects or individuals.

viAct’s EHS management system for manufacturing industry triggers immediate alerts, notifying both the forklift operator and designated personnel to take corrective action, preventing accidents and ensuring a safer working environment. This proactive approach not only mitigates risks but also fosters a culture of heightened safety awareness and compliance in forklift operations within manufacturing facilities.

2. Housekeeping Management in Food Manufacturing Industry

Housekeeping management in the food manufacturing industry is paramount for maintaining stringent hygiene standards and preventing contamination risks. AI Video Analytics introduces a transformative dimension to this aspect by bolstering housekeeping protocols through continuous monitoring and analysis. CCTVs equipped with AI technology are strategically positioned throughout manufacturing facilities to oversee cleanliness standards in real-time. These systems can detect spillages, improper waste disposal, equipment cleanliness, and adherence to sanitation procedures.

viAct’s Digital EHS Management System for food manufacturing units elevates the efficiency of housekeeping management but also ensures compliance with rigorous regulatory requirements, safeguarding the quality and safety of food products. When deviations or cleanliness issues are identified, AI-driven alerts through viAct’s smart video surveillance system (VSS) prompt immediate corrective actions, ensuring swift resolution and upholding impeccable hygiene standards essential in food production.

3. Danger Zone Access Control in EV Manufacturing Units

Implementing AI Video Analytics for electric vehicle (EV) manufacturing units is a pivotal step towards enhancing safety protocols. The areas that harbor high-risk zones where stringent safety measures are crucial, AI powered danger zone access control or intrusion detection applications become important. AI-powered systems, integrated with cameras, actively monitor and analyze these danger zones in real-time. Immediate alerts are triggered, notifying designated personnel and preventing access until compliance is ensured.

The smart video surveillance system (VSS) by viAct is a great example. Through advanced object recognition and personnel tracking, its scenario-based AI identifies unauthorized access or potential safety breaches. This includes detecting individuals attempting to enter restricted areas such as Battery assembly areas, High-voltage testing zones, Robotic assembly lines, Charging stations and battery storage areas, Welding and soldering stations. This proactive approach ensures strict adherence to safety protocols, fostering a safer working environment within EV manufacturing units.

4. PPE Compliance Monitoring in Chemical Manufacturing Units

Monitoring Personal Protective Equipment (PPE) compliance through AI Video Analytics in manufacturing industry is a groundbreaking approach for ensuring worker safety. Chemical manufacturing environments often involve exposure to toxic substances, corrosive materials, or airborne particulates that can pose severe health hazards if proper precautions aren't followed. Thus, such AI powered systems powers existing cameras with cognitive ability to actively scan the manufacturing environment for adherence to PPE protocols.

The Digital EHS Management System for manufacturing industry by viAct is trained to recognize specific PPE items such as goggles, masks, gloves, and protective clothing. The scenario-based AI system can identify instances of non-compliance in real-time. Immediate alerts are generated when employees are detected without the required PPE, ensuring swift corrective action and reducing the risks associated with chemical exposure. This integration reinforces safety standards and also creates a culture of heightened compliance, prioritizing the well-being of workers in chemical manufacturing settings.

5. Machinery Anomaly Detection in Automotive Manufacturing Industry

AI Video Analytics in automotive manufacturing industry, revolutionizes safety by detecting machinery anomalies, ensuring operational efficiency, and minimizing accidents. These systems leverage machine learning algorithms to monitor and analyze machinery performance in real-time. They can detect deviations from normal operational parameters, such as irregular vibrations, unusual sounds, or unexpected movements in manufacturing equipment.

viAct’s AI enabled EHS platform for manufacturers identifies these anomalies promptly through AI-powered systems triggering alerts, allowing for immediate intervention, maintenance, or shutdown if necessary. This proactive approach prevents potential breakdowns, reduces production downtime, and, most importantly, ensures the safety of workers by averting accidents related to malfunctioning machinery in automotive manufacturing units.

How efficient is viAct’s AI enabled EHS platform for manufacturers in reducing Total Recordable Injuries (TRIs)?

viAct’s AI-enabled EHS platform for manufacturers serves as a comprehensive solution in mitigating Total Recordable Injuries (TRIs). By analyzing EHS data trends in viAct’s intuitive dashboard, this platform identifies potential risks, analyzes historical incident patterns, and forecasts safety hazards within any manufacturing environments. Through real-time monitoring of workplace conditions, equipment performance, and employee behaviors, viAct’s proprietary scenario-based AI algorithms proactively flag potential safety issues before they escalate. These capability enables timely interventions, targeted safety training, and the implementation of corrective measures, significantly reducing Total Recordable Injuries (TRIs) in the following manner.

  • 95% Reduction in fatal slips, trips and near misses

  • 90% Lesser Incidences of PPE non-compliance related accidents

  • 10x more effective than manual surveillance

By fostering a preemptive safety culture and empowering proactive risk management, viAct’s AI video analytics for manufacturing industry diminishes TRIs and bolsters operational efficiency. Thus, viAct’s AI enabled EHS platform ensures a safer and more secure working environment for manufacturing personnel.


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