The modern manufacturing and logistics under the Industry 4.0 landscape demands a sharp focus on safety, efficiency, and productivity. With the integration of advanced technologies, they can now achieve these goals more effectively than ever before. One of the most transformative technologies in this space is video analytics.
By using viAct’s video analytics for safety in logistics and manufacturing can be elevated to the next level. With sensor integration (IoT) and multimodal input processing, the system can lead to a 95% reduction in workplace accidents.
This blog explores the critical role of such analytics in boosting safety across various operations that comprise a major part of a day-to-day manufacturing facility.
1. Protecting Workers in Close Proximity to Machines
Workers who operate in close proximity to heavy machinery face numerous hazards, from entanglement to being struck by moving parts. In 2018, the U.S. Bureau of Labor Statistics reported 20,480 workers in manufacturing being struck by objects or types of equipment and 12,790 were caught in between various pieces of equipment.
viAct’s video analytics in manufacturing addresses this issue by continuously monitoring areas around machinery, and detecting when workers enter hazardous zones. Here is how it provides its services –
Ensure PPE Compliance
Track worker movements around machines 24/7.
Automatically shut down machines when workers are in very close proximity.
This proactive approach significantly reduces the risk of accidents and acts as an omnipresent guide to the HSE teams, creating a smart manufacturing environment.
2. Addressing Occupational Health Concerns
viAct’s video analytics for safety in manufacturing can analyze workers’ postures, movements, and repetitive actions, identifying patterns that may lead to strain or injury.
For example, if a worker during it material handling task on the factory floor is consistently bending at an unsafe angle or lifting heavy objects incorrectly, the system can flag these behaviors and suggest corrective actions. This not only prevents injuries but also promotes a healthier, more sustainable work environment.
The intervention of the analytics at the right time prevented occupational illnesses which included 9,76,090 cases of musculoskeletal diseases among workers in the private sector in 2021-22. It affects the primary shoulders of workers in 36% of cases, trunk primarily in the back in 43% of cases, and knees for 15%.
This could turn into a lifelong injury if not detected at the right time. With time to time REBA and RULA ergonomic assessment using analytics, the level of injury can be substantially reduced.
3. Intrusion Detection: Preventing Unauthorized Entry and Theft
Beyond safety, the system is also essential for security in manufacturing and environments. Unauthorized entry into restricted areas, theft of valuable assets, and tampering with equipment are serious concerns that can disrupt operations and lead to significant losses.
Video analytics in manufacturing can monitor critical points in the factory floors such as –
Entry Points
Authorized personnel entry using helmet recognition
Monitoring gates with Automatic Number Plate (ANPR) recognition
If an unauthorized individual is detected in a restricted area, the system triggers alarms and notifies security personnel. This ensures that critical areas are protected from unauthorized entry, reducing the risk of theft, vandalism, and sabotage.
The role of video analytics for safety in logistics operations is equally efficient. Let’s look into the common scenarios in logistics and the input from the AI-powered surveillance system.
1. AI Video Analytics for Logistics Operations
Forklifts are indispensable in logistics operations, but they also pose significant risks if not handled properly. Accidents involving forklifts can lead to severe injuries, equipment damage, and operational delays. Video analytics plays a crucial role in preventing such incidents by providing real-time monitoring and analysis of forklift activities.
Forklift monitoring systems using viAct’s video analytics in logistics can detect unsafe driving behaviors, such as excessive speed, sharp turns, or improper load handling. It identifies operator distractions immediately such as using their phones, smoking, or being involved in a conversation with a fellow worker when operating.
This leads to the development of a safety culture in the facility as operators being aware that their activities are monitored can be more responsible and adhere to safety protocols.
2. AI Video Analytics for Risk Assessment in Logistics
In logistics operations, high-traffic areas are a common challenge. These zones, where forklifts, trucks, and workers often intersect, are particularly vulnerable to accidents. The constant movement of vehicles and personnel within confined spaces creates an environment where collisions can easily occur, leading to severe injuries, damage to goods, and costly operational delays.
For instance, in a bottling facility in the food and beverage industry, forklifts are constantly moving between storage areas, production lines, and loading docks. The high traffic and tight spaces increase the risk of collisions and accidents. To address these challenges, the facility can implement an video analytics for risk assessment in logistics.
This system continuously monitors the forklifts in operation, detecting unsafe driving behaviors such as speeding or taking sharp turns near sensitive areas like filling lines or packaging zones. When the system identifies a potential risk—such as a forklift approaching an intersection at high speed—it immediately alerts the operator and nearby personnel, allowing them to take corrective action before an accident occurs.
3. Video Analytics for Warehouse Management
In logistics, the transport of raw materials finished and unfinished products often occurs as common activities. The use of video analytics for warehouse management can help in managing such operations with safety and ease.
Considering internal monitoring in the warehouse such as monitoring proper maneuvering, adherence to speed limits, and avoiding collisions with other equipment or personnel such as pallet jacks.
Video analytics in logistics can monitor the use of elevated platforms to ensure that they are being used correctly and safely. Regular video surveillance can help identify wear and tear or potential issues with elevated platforms, prompting timely maintenance to prevent accidents.
The system can analyze external functions such as loading and unloading workflows to identify bottlenecks or inefficiencies, suggesting improvements to speed up the process and reduce downtime. It can oversee the loading of goods onto transport vehicles, and the placement of the cargo ensuring that items are secured properly to prevent damage during transit.
Let’s unfold a few thoughts on the use of video analytics in this short Q&A session –
Q1: How can video analytics for safety in manufacturing be integrated into an existing system?
viAct’s video analytics can be integrated into the existing IP camera & CCTV that connect with existing systems. It connects to the AI cloud using an RTSP link and leads to an automatic monitoring of scenarios.
Q2: What is the process for retrieving and analyzing historical data from AI video analytics for risk assessment in logistics?
Historical safety data can be retrieved by accessing archived video footage through the centralized management platform. Advanced search features and metadata tagging help quickly locate relevant incidents for analysis and reporting. Trend-oriented reports are easily generated upon setting the specification of data.
Q3: Can video analytics in manufacturing and logistics be used to provide safety training sessions?
Yes, it can be used to generate personalized safety recommendations and training sessions based on worker history. viAct Co-pilot is a safety chatbot that uses Generative AI to create data-driven actionable insights based on specific queries on manufacturing safety.
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