A common experience while walking through a factory’s shop floor is the sound of machines humming, workers busy at their stations, and the sense of productivity. This is the heart of any nation’s manufacturing sector—a vital engine driving the nation’s economic dreams. The manufacturing industry not only powers the Make in India and other ambitious initiatives in India but also shapes it’s aspiration to be in line with a global manufacturing hub. Contributing approx 16% – 19% to the GDP and employing over 27.3 million people, it’s one of the wheels of growth trajectory.

Yet, the promise of economic progress lies in a harsh reality. Factories, while producing goods that fuel the economy, also produce tragedies that should belong to a bygone industrial era. Every day, four workers lose their lives, and twelve undergo major surgeries due to accidents in Indian manufacturing units. In 2024 alone, more than 8,000 serious accidents were reported in registered factories.

The sobering reality is that our factories while producing goods that power the economy, are also producing alarming numbers of workplace casualties. Each day in Indian manufacturing plants, we witness tragedies that should belong to a bygone industrial era; however, some of the similar ongoing challenges and some are

How it can be solved by AI-vision analytics

Traditional surveillance passively records incidents, but Vision Analytics actively prevents them from using AI-driven smart surveillance real-time monitoring. it directly addresses the major challenges faced in manufacturing safety and security through practical, AI-driven solutions. Below is a comprehensive table that maps the challenges to Vision Analytics solutions

Steps Involved in Implementation for Manufacturing Safety

Step 1: Risk Assessment & Solution Mapping

• Identification of high-risk zones (assembly lines, forklift paths, chemical storage, oil storage etc)
• Prioritize implementation areas based on incident data

Step 2: Smart Camera Deployment

• AI enhancement of existing CCTV infrastructure
• Strategic placement at critical safety choke points
• Seamless integration with control rooms and IoT systems

Step 3: Real-Time Threat Prevention

• Instant safety gear violation detection (helmets, gloves, goggles, harness )
• Restricted area intrusion alerts by any person, vehicles or others
• Machine operation compliance monitoring
• Multi-channel alerts (on-site sirens, mobile push, email)

Step 4: Data-Driven Safety Recommendation

• Automated incident logging with video evidence

Step 5: Continuous Improvement

• Algorithm updates for new risk patterns
• Staff training on AI alert response protocols
• Scalable expansion across multiple facilities

After implementation, accident management in manufacturing will work in a similar process shown by below image

Expected Benefits in the manufacturing industries or factories

Post Integrating vision analytics in manufacturing units offers numerous advantages that directly impact safety and productivity:

Enhanced Safety and Risk Reduction

• Reducing potential accidents by detecting unsafe behaviours in real time.
• Minimizes human errors by ensuring compliance with safety protocols.
• Minimize the chance of fire in case of an alert.

Faster Emergency Response

• Real-time alerts allow immediate intervention, reducing the severity of incidents.
• Accurate incident recording aids in quick and accurate root cause analysis.

Data-Driven Safety Management

• Provides actionable insights into frequent safety violations and risk patterns.
• Helps managers implement targeted safety training based on incident data.

Operational Efficiency and Cost Savings

• Prevents downtime by identifying machine anomalies early, avoiding breakdowns.
• Reduces costs associated with workplace injuries, insurance claims, and legal issues.

Improved Employee Morale and Reputation

• Demonstrates a commitment to worker safety, fostering a positive workplace environment.
• Builds a reputation as a safety-conscious manufacturer, attracting skilled talent and retaining employees.

Valiance Solutions is a growing provider of AI-powered computer vision and generative AI solutions, offering effective safety and security solutions for manufacturing and factory plants. Its platform, GuardVision AI, improves workplace safety and security by providing real-time monitoring and alerts to responsive teams. Designed for configurability and scalability, GuardVision AI adapts to different factory environments, ensuring protection for both workers and assets.