Workplace safety at manufacturing units with the help of AI

When it comes to workplace safety, AI can reduce risks tenfold and help create a safer working environment by using the Internet of Things or IoT. AI in manufacturing involves using technology to automate complex tasks and unearthing previously unknown patterns in manufacturing processes or workflows. According to a BCG report, the most important AI use cases in the manufacturing industry are Intelligent, self-optimizing machines that automate production processes. McKinsey states that AI alone can generate $1.2-$2 trillion in value for manufacturing and supply chain management.

How AI Can Enhance Workplace Safety:

The wireless cameras can be placed inside the manufacturing units. And it will continuously capture footage of the space in order to detect potential hazards. The captured image is routed to the cloud. Here, the AI technologies look for patterns and SOC members are responsible for checking them on spot.

Artificial Intelligence when mixed with the Internet of Things (IoT) is yet another smart system that involves small sensors for monitoring anything from major equipment to whole manufacturing lines, workers, and just about everything else. After the sensors are installed, the Machine learning model analyses every component separately detects possible dangers, and Artificial Intelligence recommends remedies. Because Artificial Intelligence has the power to forecast future patterns, it can identify health hazards and inform you before something bad happens. To reduce possible dangers, one may establish predictive warnings and alerts all through the platform. Based on the industry, one such device has the potential to reduce the risk and minimize major casualties. Extraction, heavy metal production, and other high-risk manufacturing operations may all be made significantly secure.

People that spend too much time in intense heat, for instance, could use wearable sensors for monitoring their pulse rate, temperature levels, and so on. When the detector identifies risk, it notifies the wearer to help avoid harm. IoT provides tremendous advantages across numerous sectors, enabling complete adaptability to unique industrial demands. In addition to danger monitoring, the technology is utilized for interaction tracking to reduce the transmission of pathogens among staff. Now since you understand how Artificial Intelligence contributes to a safe and healthy workplace, it is indeed time to contemplate all advantages it offers.

Benefits of Artificial Intelligence to Improve Safety at Manufacturing Units

Artificial Intelligence is increasingly starting to spread into a variety of businesses. Manufacturing, mining, and other hazardous industries already use it as a potent accident prevention measure. Below mentioned are some of the advantages it offers in actuality.

Reduction in Human Errors

Occupational injuries are mainly caused because of mistakes made by humans.  Furthermore, a minor error might not only endanger others but could also result in delays that cost huge amounts of money.

When workers are wearied or stressed, they make mistakes. Approximately 40% of all U.S. workers find it difficult to catch up with a daily job, which surely causes serious errors. AI, on the other hand, never makes errors because it never feels fatigued. The correct machine learning model combined with the Internet of Things will help to detect when workers are wearied, detect dangerous regions, and warn employees regarding possible hazards before they occur.

Artificial Intelligence is just a tool that allows and helps you to create a safe workplace even in manufacturing units. With the implementation of AI, the workers will feel very safe and this will also help you to optimize the manufacturing unit. Human errors will no longer be the reason for your business downtime.

Dangerous Tasks can be Automated

The production robots can be made more efficient by using Artificial Intelligence and Machine Learning. Robotic production can be taken over by AI and with the help of automation, the tasks can be completed without human involvement. This will protect workers from getting into hazardous environments which might otherwise have proved lethal for them. It’s been decades since robots are used for inspecting dangerous situations.

Robots do not need any protection to enter the hazardous environment and they can send reports back from there to humans, who are comparatively in a safer place. For instance, drones have widely been used by the construction industry in the past few years and it has drastically reduced the harmful effects the workers might face by entering those environments. Instead of workers, drones evaluate and analyze the sites and send reports.

Monitoring of Employees

Every individual worker can be tracked with the help of Artificial Intelligence combined with sensors running on the Internet of Things. When it comes to reducing viral propagation, staff surveillance has shown to be quite effective. For instance, when one of the workers came back positive for COVID-19, managers may utilise the idea behind this method to identify everybody with whom they had contact while being infectious. Using this way, the cause can be immediately identified and an outbreak can be prevented.

However, worker tracking has other uses as well. Some of them are:

  • A worker’s location can easily be tracked.
  • The vital signs of every worker can be easily monitored.
  • In case of environmental hazards, workers can easily be notified.
  • Any chance of physical injuries when working in manufacturing units can be reduced.
  • Staff training can be greatly improved.

Monitoring Harassment at Manufacturing Units

Workplace bullying has long been a severe problem in businesses all around the world. 4 out of 5 women suffered some sort of sexual harassment at work, and AI can assist there as well. It can investigate harassment in the workplace and expose those guilty.

Natural language processing, or NLP, is also used by Artificial Intelligence for analysing emails as well as other documents for unsuitable terms. When one is detected, it may immediately send a notification to the office of the manager. Data may also be used to detect unfair advancements and other possible problems. AI using speech recognition may also distinguish stated terms & generate thorough statistics throughout meetings.

Detection and Prevention of Crimes

Despite having security cameras at the manufacturing units, you might never know if a crime has taken place until and unless you view the recorded videos. It is nearly impossible to stop a crime with the help of passive monitoring. However, the AI-enabled cameras send alerts on your phone as soon as they detect something suspicious. The alerts are sent in real-time and this helps to catch the one carrying out the crime.


The primary concern in the manufacturing units should always be workplace safety. Conventional ways, on the other hand, make it difficult to monitor each worker and manufacturing unit on a real-time basis. Artificial Intelligence, the Internet of Things, and certain other current technologies may help you build a respectful environment, increase overall productivity, and significantly minimise downtime.

It may also assist you in monitoring employee weariness, detecting possible risks, and ensuring your employees’ safety and welfare. Workplace safety is evolving right before our eyes, and AI applications will eventually be prepared to cut the rates of accidents and fatalities to near zero. It is basically a definite plus for both management and employees.

Recent Blogs