In the fast-paced manufacturing world, every second, every action, and every precaution matters. With heavy machinery, hazardous materials, and high-temperature operations, the factory floor is filled with potential risks.
Even though most industries put safety SOPs, audits, and awareness systems in place, compliance monitoring remains one of the toughest challenges. Despite safety kiosks, signage, and regular checks, human errors and negligence still lead to avoidable injuries and costly damage.
This is where our AI video analytics software comes in. The software helps in transforming existing CCTV systems into intelligent, proactive safety monitors that never blink.
The Human Factor: A Persistent Challenge to Safety Compliance
While most manufacturing plants have existing on-campus safety measures, including systems, kiosks, banners, and awareness tests for both visitors and employees, and brief everyone on Standard Operating Procedures (SOPs) and equip them with safety gear, the reality is often different.
Despite these efforts, employees and contractors frequently violate safety protocols inside the premises. Personal Protective Equipment (PPE) violations, like failing to wear helmets, gloves, or masks, are widespread. Manually monitoring these violations across extensive campuses is virtually impossible, especially when reliance is placed on periodic audits or occasional inspections.
Even the best efforts often fall short due to:
- Human fatigue in monitoring live CCTV footage 24×7
- Reactive systems that only help after an incident has occurred
- High cost of upgrading to AI-embedded cameras
- Lack of continuous enforcement, especially among semi-skilled or contract workers
The consequences of these gaps extend beyond the immediate risk to life, encompassing operational downtime, financial penalties from legal action, and a negative impact on employee morale and relationships.
Existing Solutions and Why They Don’t Work Long-Term
Manufacturers often try multiple safety monitoring methods, but each comes with limitations:
1. Periodic Audits & Surprise Checks
While useful, they only bring short-term behavioral change. Once the audit passes, violations often return.
2. Manual CCTV Monitoring
Relying on administrative personnel to monitor numerous camera feeds around the clock is both expensive and prone to error. The limited nature of human attention inevitably leads to mistakes. Consequently, this method is useful only for analysing incidents after they occur, offering no real preventative value
3. Expensive Edge Cameras
Many AI video analytics companies offer specialized “smart” cameras for PPE detection. But they cost up to 3x more than traditional IP cameras, a high CAPEX investment that rarely gets budget approval.
4. Entry-Only Safety Checks
While mandatory checks at entry points are effective, they don’t ensure safety compliance inside the plant, where it matters most. These limitations make it clear: the manufacturing sector needs real-time, automated safety monitoring that’s scalable and affordable.
The Solution: AI Video Analytics for Manufacturing Safety
We have developed an indigenous AI video analytics platform that ensures continuous safety compliance using your existing CCTV infrastructure, eliminating the need for expensive hardware upgrades.
Our proprietary AIVID BOT uses AI video surveillance software for PPE violation detection and unsafe behavior with 95%+ accuracy, in real time.
It identifies missing or improper use of:
Real-Time Alerts That Drive Real Change
Our AI video analysis software doesn’t just observe, it acts.
Whenever its PPE violation detection or unsafe act, an automated alert is sent to relevant supervisors in real-time. These alerts can also be displayed on LED panel and broadcast as voice warnings through connected speakers, directly notifying the violator in real time.
This simple yet powerful feedback loop leads to immediate behaviour correction, reinforcing SOPs far more effectively than posters or audits ever could.
Violation Dashboards: Delivering Actionable Insights
Our AI video analytics platform’s intuitive dashboard helps safety officers and management teams analyse patterns and trends in violations over time.
You can see:
- Which areas report the most violations
- Common repeat offences
- Shift-wise or department-wise compliance patterns
These insights allow leadership to make data-backed safety decisions, ensuring continuous improvement and accountability.
Continuous Learning and Upgrades
Our AI video analytics software for manufacturing is trained on real-world footage across various lighting conditions, camera angles, and industries.
As part of the subscription, customers receive free AI model upgrades enabling them to adapt to new safety requirements and unique scenarios.
Need to detect a new PPE type or rule?
No problem. Our AI BOT can be quickly retrained to detect custom violations, without compromising on accuracy.
Why Manufacturers Choose AIVID.AI
Our AI video analytics software for manufacturing is trained on real-world footage across various lighting conditions, camera angles, and industries.
As part of the subscription, customers receive free AI model upgrades enabling them to adapt to new safety requirements and unique scenarios.
Need to detect a new PPE type or rule?
No problem. Our AI BOT can be quickly retrained to detect custom violations, without compromising on accuracy.