AI-Driven Safety in a High-Risk Chemical Facility

A leading chemical manufacturing plant implemented an AI-driven vision system to enhance workplace safety, automate hazard detection, and improve compliance.

Impact

Results In Numbers

800%
Increase in Near-Miss Reporting
Enhanced hazard detection and automated incident logging provided safety teams with deeper insights into potential risks, allowing them to address issues proactively.
4x
Faster Emergency Response
Immediate alerts for man-down incidents ensured that distressed workers received assistance faster, reducing the severity of injuries.
83%
Reduction in Unauthorized Zone Entries
AI-driven tracking helped enforce restricted area access rules, preventing potential safety violations.
Why it matters

The Challenge

Enhancing Safety Compliance & Incident Response

Operating within the high-risk chemical industry, maintaining stringent safety protocols is a top priority. A leading European consumer goods manufacturer sought to leverage artificial intelligence to revolutionize its safety procedures. With thousands of employees operating heavy machinery, hazardous materials, and complex workflows, ensuring compliance with safety regulations was an ongoing challenge.

Recognizing the need for an advanced safety monitoring solution, the company turned to cutting-edge AI-powered vision technology. By implementing an intelligent computer vision system across their vast production facility, they aimed to create a safer, more responsive, and data-driven safety environment.

Traditional safety monitoring methods relied heavily on manual supervision and periodic inspections, leaving gaps in hazard detection and incident response. Key safety challenges included:

  • Inefficient PPE Compliance Monitoring: Ensuring that all employees wore the required personal protective equipment (PPE) in designated areas was difficult to enforce manually.
  • Slow Response to Worker Distress: In emergency situations, delays in identifying workers in distress (e.g., man-down scenarios) posed a significant risk.
  • Unsafe Movements & Zone Violations: The complexity of factory layouts led to frequent unauthorized access to hazardous zones, increasing accident risks.
  • Limited Visibility on Near-Miss Incidents: The lack of data-driven reporting meant that potential hazards were often overlooked, reducing opportunities for proactive risk mitigation.

With the scale of operations growing, it became clear that a more proactive, automated, and scalable approach to workplace safety was required.

testimonial

Word from our client

The AI-driven vision system has transformed our approach to workplace safety. Real-time monitoring and automated alerts have significantly reduced risks, improved compliance, and created a safer environment for our workforce.

Leading Chemical Manufacturer
Safety Manager
How we did it

The Solution

AI-Powered Vision for Real-Time Safety Monitoring

To address these challenges, the factory deployed a state-of-the-art AI-powered vision system that combined machine learning, image processing, and real-time analytics. A network of 30 strategically placed cameras was installed to automate safety monitoring and incident detection. The system's key capabilities included:

  • PPE Compliance Supervision: The AI system automatically detected whether employees were wearing appropriate PPE, ensuring strict adherence to safety regulations.
  • Automated Man-Down Detection: The system identified and alerted response teams immediately when a worker collapsed or remained motionless for a prolonged period.
  • Restricted Zone & Hazard Monitoring: AI-driven analytics tracked unauthorized personnel entering high-risk areas, reducing zone violation incidents.
  • Forklift & Vehicle Interaction Alerts: By monitoring the distance between workers and moving vehicles, the system helped prevent accidents in forklift-operating zones.
  • Housekeeping & Obstruction Detection: The AI system identified unsafe conditions such as cluttered pathways or misplaced materials that could pose tripping hazards.
  • Data-Driven Safety Insights: The solution provided comprehensive reporting and real-time alerts, allowing safety managers to make informed decisions and improve hazard mitigation strategies.

By replacing reactive manual monitoring with real-time AI-driven oversight, the company significantly improved its ability to enforce safety protocols and prevent workplace accidents.

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THE FINAL RESULTS

The Outcome

A Safer, Smarter, and More Compliant Workplace

The implementation of AI-powered safety monitoring delivered remarkable improvements in workplace safety, operational efficiency, and compliance:

  • 800% Increase in Near-Miss Reporting: Enhanced hazard detection and automated incident logging provided safety teams with deeper insights into potential risks, allowing them to address issues proactively.
  • Faster Emergency Response: Immediate alerts for man-down incidents ensured that distressed workers received assistance faster, reducing the severity of injuries.
  • Higher PPE Compliance Rates: Automated monitoring significantly increased adherence to protective equipment policies, reducing exposure to hazardous materials.
  • Reduction in Unauthorized Zone Entries: AI-driven tracking helped enforce restricted area access rules, preventing potential safety violations.
  • Improved Operational Efficiency: By automating safety supervision, the factory optimized its workforce allocation, reducing the need for constant manual inspections.

Through the integration of AI-driven vision technology, the company not only enhanced workplace safety but also set a new standard for proactive hazard management in the chemical industry. This transformation underscores the power of AI in fostering a safer, more compliant, and data-driven operational environment.

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