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:
- Safety Standards Monitoring: Ensuring safety standards in the finished goods area, located adjacent to the packing hall, was challenging due to its isolation.
- 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.
- 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:
- Advanced Inspection Camera (AIC): AIC technology was integrated with an NVIDIA RTX GPU for real-time video analysis.
- HSE Software Framework: A custom Health, Safety, and Environment (HSE) software framework was developed to monitor safety compliance.
- DeepStream: DeepStream technology enhanced video analytics and safety monitoring capabilities.
- High-Resolution CCTV Cameras: High-resolution CCTV cameras were deployed to capture detailed footage.
- Desktop UI: A user-friendly desktop user interface allowed real-time monitoring and intervention.
- 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:
- 100% Violation Detection: The system detected and notified all safety violations, enabling immediate intervention.
- Immediate Alarms: Immediate alarms provided timely caution to prevent accidents.
- Event Clips and Reports: Clips and reports generated by the system facilitated safety officers in addressing violations through counseling and awareness training.
- 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.