How Computer Vision Makes Factories Safer

The manufacturing industry has been utilizing technologies for digitalization. Yet, even with the different technologies at play, the manufacturing industry has been one of the largest contributors of workplace injuries. With the UN claiming 2.78 million deaths every year due to workplace-related accidents and sicknesses, safety is a major issue.

So, what can be done to address the risk of operating heavy machinery and handling hazardous material? Do they have to change the industrial practices? Is it going to be another technology?

Computer Vision helps industries keep a close eye on the happenings in their facility and help the authorities successfully implement the set guidelines. It also provides real-time alerts to the authorities when something goes wrong. Thus, they are in a better position to act swiftly and mitigate the same.

Let’s talk in detail about the role of Computer Vision in helping manufacturers mitigate risks, promote safety and protect their workforce.

How Computer Vision Makes Factories Safer

Computer Vision uses advanced cameras and AI systems to analyze visual data. It’s like a continuous monitoring system that gives intelligent alerts and helps enforcing the safety protocols.

Here’s how computer vision is shaping a safer manufacturing landscape:

1. Monitoring Worker Movements

Unintentional entry into hazardous zones is one of the leading causes of workplace injuries in manufacturing. Workers may accidentally step into areas where heavy machinery is in operation or approach zones with harmful chemicals.

How It Helps:
Computer vision systems track the precise location and movement of workers on the factory floor. They create virtual boundaries around dangerous areas, ensuring employees stay within safe zones. These systems can identify risky movements, such as walking into the path of a moving conveyor crane or nearing a high-temperature furnace, and trigger alerts to warn the worker or halt machinery to prevent accidents.

Additionally, these systems can adapt to dynamic environments by:

• Tracking multiple individuals simultaneously across vast facilities.
• Learning patterns of movement to differentiate between routine and unusual activity.

2. Enforcing Safety Guidelines

Enforcing the safety measures and continuous monitoring of the adherence is made easy by Computer Vision. It checks for protective measures like wearing helmets, gloves, goggles and protective suits.

How It Helps:
Computer vision automates the enforcement of safety rules by monitoring compliance with protective gear requirements. Cameras equipped with AI can:

• Detect if workers are not wearing required safety gear and notify supervisors instantly.
• Identify distractions, such as phone usage near operational machinery.

For example, in chemical plants, workers entering mixing units without full protective suits can be flagged immediately, reducing the risk of exposure. By removing human bias and fatigue, computer vision ensures consistent enforcement, even during peak production hours.

3. Monitoring Machinery and the Environment

Malfunctioning machinery and unsafe environmental conditions can lead to dangerous accidents. Continuous surveillance of equipment breakdowns, leaks, or fires is much needed.

How It Helps:
Computer vision-powered sensors continuously monitor factory environments to ensure operational safety. These systems can:

• Identify wear and tear in machinery by analyzing visual data, helping predict maintenance needs before failures occur.
• Monitor moving machinery, such as robotic arms or assembly lines, and create virtual safety perimeters to prevent worker-machine collisions.
• Detect hazardous gas leaks, chemical spills, or temperature spikes in real time, triggering evacuation protocols to protect employees.

For instance, sensors in a paint shop can detect harmful fumes and activate ventilation systems automatically. In factories handling flammable substances, cameras can spot sparks or overheating components, preventing fires before they ignite.

4. Preventing Trespassing and External Threats

Manufacturing plants are generally of large sizes, due to which they are vulnerable to trespassing by intruders or even wildlife. This is a risk to the workforce, property and operations.

How It Helps:
Computer vision systems can monitor vast perimeters 24/7, identifying and analyzing suspicious activities. They can:

• Differentiate between humans, animals, and vehicles using advanced object recognition.
• Raise alarms or activate security protocols when unauthorized access is detected.

For example, the system alerts the authorities if an unauthorized person tries to enter a restricted zone or if there is an animal in the way or the premises.

5. Identifying Unsafe Behaviors

Improper handling of machinery or ignoring safety signs most likely leads to workplace injuries. However, workers often skip steps in safety protocols to save time, leading to increased risks.

How It Helps:
Computer vision analyzes behavior patterns and flags unsafe actions in real time. It can:

• Identify workers operating machinery without adequate training.
• Detect when employees bypass safety barriers, climb onto machinery, or use improper tools.
• Alert management to workers engaging in risky behavior repeatedly, enabling targeted retraining.

For instance, suppose a working is manually adjusting a working robotic arm in an automotive assembly plant, the system might right away notify the supervisor. The swift action can prevent potential injury.

6. Easing Incident Investigations

When accidents occur, finding out the causes is important to prevent it from happening again. But if the data is not enough, it is not possible to identify the actions that led to the accident.

How It Helps:
Computer vision systems provide detailed video logs of incidents, enabling faster, more accurate investigations. They can:

• Reconstruct events leading up to an accident to pinpoint the cause.
• Highlight lapses in protocol, such as missed maintenance checks or ignored safety warnings.
• Provide evidence to ensure accountability and improve future safety measures.

This approach helps in resolving incidents and provides opportunities to refine safety strategies.

7. Faster Emergency Responses

Timely response means everything during an emergency. If there is a delay in acting to fires, gas leaks, or medical emergencies, the consequences are severe.

How It Helps:
Computer vision systems are designed to recognize emergencies instantly. They can:

• Identify unusual occurrences like a worker collapsing or flames breaking out.
• Send immediate alerts to responders with precise location details.
• Integrate with fire suppression or emergency evacuation systems for rapid action.

For example, in a factory handling flammable materials, the system can detect smoke and automatically trigger sprinklers while notifying the fire department, reducing response times and potential damage.

Building a Safer Future with Computer Vision

Computer Vision has introduced a paradigm shift in safety for industries. By continuously checking the safety of the workers and the workplace, it acts like a supervisor who works 24/7, totally dedicated to ensuring safety.

Want to understand how AI Computer Vision can make your plant safer? Get in touch with us for a free consultation.