AI-Driven Safety Transformation at Orlen

Orlen’s refinery operations involved the hazardous process of loading tanker trucks with liquid asphalt at temperatures exceeding 200°C. This demanding and high-risk task required strict adherence to safety protocols to prevent severe injuries and operational disruptions. Given the extreme temperatures and the nature of the materials being handled, any lapse in safety procedures could lead to catastrophic incidents, affecting not only employees but also the overall efficiency of operations. Employees and truck drivers were exposed to considerable risks, including severe burns and respiratory hazards due to inadequate use of Personal Protective Equipment (PPE) such as face shields. Despite existing safety measures, compliance was inconsistent, leading to recurring incidents and close calls. The complexity of the working environment, combined with human factors such as fatigue and distractions, made traditional safety monitoring insufficient.

Recognizing the need for a more effective approach, Orlen identified several key challenges that needed to be addressed:

• Non-compliance with PPE requirements, exposing workers to severe burn risks.
• Limited visibility into real-time safety violations and near-misses.
• Delayed response times to incidents, increasing operational risks and downtime.
• Difficulty in educating and monitoring third-party contractors unfamiliar with site safety protocols.
• Absence of actionable data to identify trends in unsafe behaviors.

To mitigate these risks, Orlen deployed Surveily AI, seamlessly integrating it into their existing CCTV infrastructure while leveraging the expertise of the Health and Safety (HSE) department to drive safety improvements. The collaboration between AI technology and HSE specialists allowed for an optimized safety approach, combining real-time insights with targeted interventions. The AI-driven safety solution enabled real-time monitoring, automated safety alerts, and data-driven decision-making, focusing on:

• PPE Compliance Monitoring: AI-powered detection ensured proper use of face shields, helmets, and high-visibility vests, sending real-time alerts for non-compliance.
• Incident Detection & Response: Automated recognition of unsafe behaviors, such as improper handling of hazardous materials or unauthorized access to restricted areas, enabling immediate intervention. HSE specialists used AI-driven reports to conduct root cause analyses and develop improved response protocols, ensuring rapid and effective handling of safety violations.
• Automated Safety Reporting: AI continuously analyzed video footage, generating insights on safety trends and high-risk behaviors, helping refine training and intervention strategies. The HSE team utilized this data to establish new safety KPIs, measure ongoing compliance, and proactively address emerging risks.
• Smart Device Integration: Surveily AI activated real-time safety mechanisms such as warning lights and audio alerts, reinforcing immediate hazard awareness.
• Behavioral Shift & Training Enhancement: Instead of penalizing workers, AI-generated insights were used for coaching and fostering a proactive safety culture. The HSE department launched a data-backed training program, using AI-recorded incidents as case studies to educate employees and contractors on best safety practices. These training sessions resulted in heightened awareness and a more engaged workforce, actively contributing to a safer environment.

The implementation of Surveily AI brought a paradigm shift in how safety was managed at Orlen’s refinery. The AI-powered system allowed for real-time monitoring, faster response to potential hazards, and a data-driven approach to incident prevention. Employees and contractors alike benefited from a more structured and informed safety framework. The deployment led to significant improvements across multiple key safety metrics, demonstrating the effectiveness of AI-driven interventions. The tangible results included:

• 75% reduction in workplace incidents within the first 16 weeks.
• 95% PPE compliance achieved after six months.
• 35% decrease in unsafe behaviors in the first two weeks of implementation.
• 50% faster response times to critical safety incidents, minimizing risks and operational downtime.
• Enhanced contractor safety awareness, leading to improved adherence to site regulations.
• Positive shift in workplace culture, with employees embracing AI as a safety enhancement rather than a surveillance tool.

Beyond just statistics, the implementation of Surveily AI fundamentally changed how safety was perceived at Orlen. Workers who initially viewed safety measures as restrictive began to appreciate their value in ensuring their well-being. Employees became more proactive in adhering to PPE requirements, and safety discussions became more data-driven and constructive.

Additionally, the ability to analyze and predict risk patterns allowed Orlen's Health and Safety (HSE) team to refine their safety protocols continuously. The organization also introduced interactive training sessions using AI-generated incident data, helping to create a deeper understanding of potential hazards.

Conclusion: Pioneering the Future of Industrial Safety with AI

By implementing Surveily AI, Orlen revolutionized its safety protocols, shifting from reactive incident management to proactive prevention. The AI-powered solution significantly improved PPE compliance, expedited incident detection, and fostered a culture of continuous safety improvement.

Orlen’s success serves as a benchmark for the oil and gas industry, demonstrating how AI-driven safety solutions can drive tangible enhancements while empowering employees and HSE teams alike. As AI technology evolves, Orlen is now exploring further expansions of Surveily AI to additional facilities, reinforcing its leadership in workplace safety innovation.