AI-Driven Safety Revolution: Empowering a Global Beverage Leader to Achieve Zero Incidents [Success story]

Abstract

In a fast-paced manufacturing environment, safety is paramount. This article outlines how Seewise's Vision AI-driven human presence monitoring system revolutionized safety protocols at a leading global beverage manufacturing plant. By integrating advanced vision AI with existing manufacturing systems, Seewise helped mitigate human-machine interaction risks, achieve near-zero incidents, and optimize compliance with safety standards.

Introduction

Workplace safety in industrial settings is a critical challenge, particularly in high-throughput environments like beverage manufacturing. The risks associated with human-machine interactions, especially near palletizers and stretch wrappers, demand innovative solutions that combine real-time monitoring with automated intervention capabilities.

Seewise's Vision AI-powered system addresses this gap by providing a robust framework for detecting and preventing human-machine safety violations. By leveraging computer vision technology over CCTV cameras and seamless integration with existing PLC/SCADA (Programmable Logic Controller) systems, the solution delivers real-time alerts, machine control, and actionable insights to create a zero-incident workspace.

Challenges in Modern Manufacturing

Manufacturing plants face the following safety challenges:

• Human Presence in Restricted Areas:Operators entering unsafe zones during machine operation.
• Manual Oversight Gaps: Reliance on human supervision increases the likelihood of unreported incidents
• Inefficient Response Mechanisms: Delays in identifying and mitigating risks.
• Compliance and Accountability: Difficulty in tracking and maintaining adherence to safety protocols.

The Seewise Solution

Core Features

Seewise's vision-based AI system tackles these challenges with an end-to-end safety solution that includes:

• Real-Time Human Detection: Monitors restricted zones and detects operator presence near active machinery.
• Automated Machine Intervention: Instantly communicates with PLCs to halt machine operations upon detecting a safety violation.
• Customizable Alerts: Triggers real-time alarms, including audible signals and email notifications.
• Data-Driven Insights: Provides dashboards showcasing safety compliance scores, violation trends, and spatial analytics.

Integration with Existing Systems

• Hardware: High-resolution CCTV IP cameras deployed strategically near critical machinery
• Software: AI models trained to recognize human presence with 95%+ accuracy after on-site calibration.
• PLC Communication: Bi-directional communication with controllers to stop or restart machines based on detected activity.

Implementation Workflow

• Site Assessment: Determine optimal camera placement and system integration points.
• Model Training: Collect and label video data from the site to train AI models.
• System Deployment: Install hardware and software, ensuring seamless communication with on-premise PLCs.
• Remote Fine-Tuning: Continuously improve model accuracy with live data during the pilot phase.
• User Acceptance Testing (UAT): Validate performance with the client’s safety and operations teams.

Impact and Outcomes

Key Results

• Zero Incident Rate Achieved: Reduction in human presence violations in restricted areas.
• 99%+ Accuracy: High precision in detecting unsafe activities during active machine operations.
• Compliance Optimization: Improved adherence to safety protocols, reflected in higher compliance scores.
• Operational Efficiency: Decreased machine downtime caused by safety incidents.
• Scalability: Repeat orders from the client demonstrate trust and the system's adaptability for other locations.

ROI and Long-Term Value

• Cost Savings:Reduced liability from workplace accidents and machine downtime.
• Safety Culture: A data-backed safety-first environment, reinforcing employee trust and regulatory compliance
• Future-Ready Platform: The AI model’s adaptability allows expansion to other processes and facilities.

Replicating Success Across Industries

Seewise’s LVM (Large Vision Model) solution has proven its potential to create safer work environments in high-risk, high-output industries. Its modular design ensures seamless customization for sectors like automotive, FMCG, logistics, and beyond. The system's core functionalities can be tailored to suit diverse operational needs, enabling scalable adoption.