Revolutionizing Steel Mill Safety with AI-Powered Surveillance

Steel production is one of the most hazardous industrial environments, with high risks associated with heavy machinery, crane operations, and manual loading processes. A global steel manufacturer sought to improve worker safety by addressing critical risks in its logistics operations, particularly during steel loading. The company turned to Surveily’s AI-driven computer vision solution to enhance safety monitoring and compliance enforcement.

The steel mill faced multiple recurring safety concerns that created a hazardous work environment:

• Workers Entering Hazardous Zones: Employees frequently moved into restricted areas beneath crane operations, increasing the risk of severe injuries or fatalities due to falling loads or machinery movement.
• Lack of Real-Time Monitoring: Safety personnel relied on manual inspections and post-incident reviews, making it difficult to prevent accidents proactively.
• PPE Non-Compliance: Workers occasionally failed to wear mandated protective gear, such as helmets and high-visibility vests, heightening their risk of injury.
• Truck Wheel Blockade Violations: Trucks were often parked without applying wheel blockades, leading to unintended movements and potential collision hazards.
• Limited Data-Driven Insights: The absence of automated tracking made it difficult to identify trends in non-compliance and enforce targeted safety interventions.

These safety issues led to frequent safety violations, operational inefficiencies, and an increased risk of workplace injuries. The company required a proactive, real-time monitoring solution to ensure continuous compliance and improve worker safety.

To mitigate these safety challenges, the steel manufacturer implemented Surveily’s AI-driven computer vision solution, which introduced several key improvements:

• Advanced Zone Safety Detection: AI-powered cameras were deployed to continuously monitor hazardous zones. The system detected unauthorized presence beneath crane operations, issuing instant alerts to both workers and supervisors, preventing potential accidents.
• PPE Compliance Enforcement: The system identified workers not wearing required PPE, triggering real-time alerts and ensuring continuous compliance.
• Automated Truck Wheel Blockade Monitoring: AI cameras verified that parked trucks had their wheel blockades engaged, preventing accidental vehicle movement and enhancing site safety.
• Real-Time Notifications and Alerts: Safety managers received immediate notifications when violations occurred, enabling faster intervention and incident prevention.
• Automated Safety Reporting: The system generated weekly and monthly reports on safety violations, offering actionable insights for targeted improvements.
• Scalable Integration: The solution seamlessly integrated with the steel mill’s existing safety infrastructure, ensuring minimal disruption and a smooth transition to automated safety monitoring.

The deployment of Surveily’s technology transformed the steel manufacturer’s safety landscape. The results included:

• 90% Reduction in Total Safety Alerts: A substantial decrease in workplace safety violations.
• 92% Reduction in Near-Traverse Alerts: Workers were effectively deterred from stepping into hazardous areas.
• 77% Reduction in Truck Wheel Blockade Alerts: Proper compliance with safety measures was ensured.
• 73% Reduction in PPE Non-Compliance Alerts: A drastic improvement in adherence to personal protective equipment requirements.

Beyond numerical improvements, the solution fostered a culture of safety awareness, ensuring workers were continuously protected. The proactive approach significantly enhanced regulatory compliance, reduced liability, and minimized workplace injuries.

Additionally, the availability of 24/7 safety data allowed safety managers to monitor workplace risks at all times, including during night shifts and weekends. This ensured that incidents could be addressed immediately, even in off-peak hours, leading to a safer and more responsive operational environment.

The safety department also launched targeted awareness campaigns based on real-time insights provided by the AI system. By analyzing recurring safety violations, the company conducted tailored training sessions and awareness programs to reinforce safety protocols and best practices. These initiatives not only reduced incidents but also instilled a long-term commitment to safety across all levels of the organization.

Conclusion: Setting a New Safety Standard in the Steel Industry

The steel manufacturer’s success story demonstrates how AI and computer vision can revolutionize workplace safety in high-risk industries. By implementing Surveily’s intelligent monitoring system, the company not only reduced incidents but also established a proactive safety culture. As the industry continues to embrace digital transformation, AI-powered solutions are becoming essential in safeguarding workers and ensuring operational efficiency.

Surveily’s technology has set a new benchmark for safety standards in steel production, proving that AI-driven innovation is the future of workplace safety.