Workplace Safety

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Enhancing Workplace Safety at a Manufacturing Facility: A Case Study in Digital Safety Monitoring

Client: A subsidiary of a British-Dutch manufacturing company, with a diverse product portfolio including foods, beverages, cleaning agents, personal care products, water purifiers, and consumer goods.

Problem: The personal care products factory in Khamgaon, Maharashtra, was committed to achieving zero accidents but faced several safety challenges:

  1. Safety Standards Monitoring: Ensuring safety standards in the finished goods area, located adjacent to the packing hall, was challenging due to its isolation.
  2. Lack of Personal Protective Gear Compliance: Employees often failed to wear essential safety gear like helmets, which was especially risky as loose boxes were stored overhead.
  3. Forklift Safety: With forklifts maneuvering in the area, maintaining safe distances and speeds between people and vehicles was crucial.

Solution: The company implemented a robust safety solution to address these challenges:

  1. Advanced Inspection Camera (AIC): AIC technology was integrated with an NVIDIA RTX GPU for real-time video analysis.
  2. HSE Software Framework: A custom Health, Safety, and Environment (HSE) software framework was developed to monitor safety compliance.
  3. DeepStream: DeepStream technology enhanced video analytics and safety monitoring capabilities.
  4. High-Resolution CCTV Cameras: High-resolution CCTV cameras were deployed to capture detailed footage.
  5. Desktop UI: A user-friendly desktop user interface allowed real-time monitoring and intervention.
  6. PLC Panel and Email Notifications: PLC panels triggered alarms, and email notifications were sent for safety violations, unsafe acts, near misses, and unsafe conditions.


The implementation of this comprehensive safety solution yielded significant improvements:

  1. 100% Violation Detection: The system detected and notified all safety violations, enabling immediate intervention.
  2. Immediate Alarms: Immediate alarms provided timely caution to prevent accidents.
  3. Event Clips and Reports: Clips and reports generated by the system facilitated safety officers in addressing violations through counseling and awareness training.
  4. Digitized Safety Monitoring: The digitized safety monitoring system brought efficiency and precision to safety management.

In conclusion, the company’s commitment to workplace safety and the adoption of cutting-edge technology for safety monitoring and compliance significantly enhanced their safety culture. This case study showcases how digital solutions can revolutionize safety practices, creating a safer working environment and aligning with the vision of zero accidents.

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