PPE Detection & Safety Compliance System

Client Profile

A large-scale manufacturing plant with 700+ workers across 10 high-risk zones (Electrical, furnaces, conveyors, chemical storage). Prior to deployment, the plant recorded an average of 18 PPE violations per week, including missing hardhats and safety vests, leading to repeated safety citations and near‑miss incidents.

Key Challenges

• ✗ Manual safety audits missed 60% of violations
• ✗ No real-time alerting for PPE non‑compliance
• ✗ Difficulty tracking repeated offenders across shifts
• ✗ Regulatory pressure for digital safety logs
• ✗ High false alarms from legacy motion sensors

Phase 1 – Assessment

Camera placement audit, lighting analysis, and model calibration (2 weeks).

Phase 2 – Hardware Integration

Upgraded 24 existing IP cameras to 4K, added edge AI servers (3 weeks).

Phase 3 – AI Training & Testing

Fine‑tuned detection models for factory environment, achieved 98.7% accuracy (2 weeks).

Phase 4 – Go‑Live & Training

Staff orientation, supervisor dashboard training, and alert protocol rollout (1 week).

Safety Impact

• 73% reduction in weekly PPE violations (18 → 4.8)
• Zero lost‑time incidents related to head/eye injuries in 12 months
• 92% faster response to non‑compliance (from 15 min to <10 sec)
• Improved safety audit score from 74% to 96%

Financial & Operational

• ₹28 lakh annual savings in potential fines and accident costs
• 40% reduction in manual safety patrol hours
• ROI achieved in 8 months
• Insurance premium reduced by 12% due to verifiable safety compliance