The manufacturing industry has undergone a colossal transformation in the last decade with the advent of Industry 4.0. This concept familiarizes the industry with smart manufacturing that utilizes real-time data to boost efficiency, productivity, and safety. The ability to drive innovation and face global challenges amplified more than any previous time.
Driving this transformation is computer vision—a technology that makes use of Artificial Intelligence (AI) to enhance various facets of manufacturing. From ensuring worker safety to optimizing vehicle operations and improving product quality, it is setting new benchmarks in setting up smart factories all around.
viAct, a pioneer in AI-driven solutions is revolutionizing the manufacturing sector with its innovative technology. With a continuous focus on using advanced AI methods for the betterment of the working environment, there are numerous modules designed to cater to the needs of the sector.
Here, we shed light on the top 5 use cases of viAct’s computer vision in manufacturing:
1. Eyes on Safety: Ensuring Worker Safety with AI
U.S. Bureau of Labor Statistics mentioned 3,73,300 recordable cases of non-fatal injuries and 341 fatal incidents in the manufacturing sector in 2020. |
The concern for worker safety in the manufacturing sector is increasing. With the estimated cost of job injuries and illnesses ranging between $176 billion to $352 billion yearly, the manufacturers are under constant risk of escalated workplace incidents leading to human and resource losses.
One of the challenges that contributes to increased safety risks in the sector is the reliance on manual monitoring processes of surveillance. The use of the tool powered by AI can with automated incident analysis and reporting that can prevent accidents in real-time.
Imagine a steel manufacturing facility where welding equipment is being operated for fabricating the structures. The workers pose risks which include burns, eye injuries from bright light, and inhalation of hazardous fumes.
With viAct’s AI-powered safety monitoring system, the following precautions are identified instantly –
The technology-enabled supervision allows to detection of similar instances across different manufacturing units and prevents accidents to a large extent. The use of technology minimizes direct human interaction in and around hazardous machinery on a factory floor impacting directly on the safety levels.
From ensuring the mandatory use of protective equipment such as helmets & gloves to identifying a potential breach at the worksite, the technology uses advanced recognition systems to track worker movement and protect them from workplace accidents.
2. Vehicle Vision: Enhancing Forklifting Operations
The manufacturing facilities include a large number of mobile plants that work in close proximity to workers and vehicles. According to OSHA, forklifts are the reason for a substantial number of accidents across workplaces. To spread awareness about the safe use of forklifts, the National Forklift Safety Day by the UK Material Handling Association is celebrated to lay focus on the 7 stages of a forklift incident cycle.
Computer vision technology involves the use of video analytics to specify the risky areas of forklifting and manage them with zero blind spots. While forklift monitoring systems allow for digitized tracking, here is how they can effectively manage common operations.
Closely monitor operator behavior such as distraction detection, not wearing a seatbelt or required PPE, and engagement in unsafe acts such as using mobile phones or smoking.
Manage balanced loading and unloading using AI-powered sensors and computer vision to assist in precise positioning and handling, reducing damage to goods.
Collison avoidance using automated fleet tracking with real-time GPS tagging of vehicles.
Ensuring pedestrian safety on the factory floor by reporting proximity, unusual traffic congestions, forward collision warning, automatic speed control, and avoidance of blind spots.
Using AI algorithms to analyze the layout of the facility and the current location of forklifts to determine the most efficient routes, reducing travel time and fuel consumption.
viMAC is an AI-based monitoring device that uses AI processors in IP cameras to detect collisions around forklifts especially when other mobile vehicles are involved. With the ability to cover 6M horizontally and 5M vertically, the installation of it on the vehicle can provide even a 900 downward visualization. It is efficient in –
Lifting Object Recognition
Tracking Machinery Operation
Operator Distraction Detection
Danger Zone Detection
Intrusion detection
The common operational areas in manufacturing involving forklifts along with other vehicles in the picture can be overcome smoothly by the integration of such smart tools facilitated by AI.
From detecting humans working in close proximity to vehicles to avoiding collisions with other mobile plants such as pallet jacks, cranes, and elevated platforms, forklift operations with technology have gained much control.
3. Product Perfection: Quality Control with Precision
The most essential output from any manufacturing facility is the quality of the product. The use of computer vision acts as an active tool to ensure the optimum quality of products. In the automotive industry, it is used extensively for detecting anomalies such as misalignments, foreign objects, and surface defects.
The textile industry uses it primarily to inspect fabrics for defects such as tears, stains, and color inconsistencies. Even in agriculture, the grading and sorting of fruits and vegetables utilises the above technology.
Across these areas, the viAct’s AI-powered video analytics mainly involves providing –
Early Defect Detection
Automated Stock Alerts
Automated Product Counting in the Assembly Line
Machinery Fault Detection
Conveyor Belt Breakdown
Blockage Detection
The AI-powered safety monitoring system helps in detecting the defects in produced goods at an early stage. It helps reduce unplanned downtime by identifying any faults in the machines, conveyor belts, or blockage around.
The automated alerts from video feeds of empty shelves or containers to restock resources help in not encountering a second of idle time. The product count in assembly lines is always recorded in the database for investigation at any point in time.
4. Seeing Beyond: Compliance with EHS in Manufacturing
Manufacturers are under constant pressure to comply with strict Environmental Health and Safety (EHS) standards, which aim to protect workers, the environment, and the community. With the advent of advanced technologies, particularly computer vision, the task of maintaining compliance has become more manageable and effective.
As per the U.S. Bureau of Labor Statistics, there are 2.8 million injury and illness cases reported by employers in the year 2022. It shows a 7.5% rise from 2021. There are several areas of concern when it relates to occupational illnesses that occur in workers due to the nature of work.
One of how the most common forms of occupational illnesses arising from musculoskeletal disease can be prevented using such technology. The ergonomic assessments using REBA and RULA using the Digital EHSS Monitoring System facilitate the automatic monitoring of workers' postures, hours spent without movement, and detection of disorder symptoms.
The workers involved in the task of packaging in a manufacturing facility spend hours in the same position. viAct’s AI-powered video analytics makes use of their assessment to detect –
Employ the NIOSH lifting equation for manual lifting tasks.
Evaluate joint angles for swift identification.
Immediate alert to correct posture.
Generate overall scores for evaluation from time to time.
Recommend personalized correcting ideas from collected data.
Apart from health and safety, the system acts as a medium for environmental monitoring as well. It continuously engages in monitoring emissions, waste disposal, and water quality. The role of AI in improving ESG scores can be effective as it helps to improve waste management by around 70%. Moreover, the principles of lean manufacturing to eliminate waste for an overall improvement in the process is sufficiently achievable with the aid of this tech.
5. Guardian of the Plant: Ensuring Plant-Wide Safety
Accurate record-keeping and regular audits are essential components of an effective safety management system. For example, in the food and beverage industry, maintaining hygiene and safety is crucial. The use of the technology to provide detailed reports on hygiene standards and generate alerts for any deviations.
viAct’s provision significantly enhances these processes by automating data collection, analysis, and reporting. They ensure that safety protocols are followed, provide evidence of compliance, and help identify areas for improvement.
The use of AI-powered safety monitoring has a systematized method of utilizing the collected data.
Step 1 – Automated Data Collection – Includes footage of worker activities, machinery operations, and environmental conditions.
Step 2 - Real-Time Analysis and Alerts – Prompt alerts are generated to notify deviations.
Step 3 - Detailed Reporting - Generates detailed reports on various safety metrics, such as PPE compliance rates, incident occurrences including slips, trips & falls, and machinery performance in its intuitive dashboard viHUB.
Step 4 – Auditing – The data can be stored in the cloud using an RTSP link for the desired period and auditors can review visual data, analyze trends, and assess the effectiveness of safety protocols.
The storage of large volumes of data allows the system to recognize patterns and suggest corrective courses of action in the future. This leads to an omnipresent supervisor guiding the factory floors at all times without human intervention.
viAct’s computer vision technology is transforming the manufacturing sector by providing innovative solutions for quality control, safety, equipment monitoring, and environmental monitoring. As manufacturers continue to embrace Industry 4.0 and lean manufacturing principles, the adoption of advanced technologies like viAct will be crucial in maintaining competitiveness, enhancing efficiency, and ensuring safety in manufacturing operations.
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