Achieving Zero Accidents with Artificial Intelligence in Manufacturing

As the word is riding with innovations, a small mistake or fault can lead to human disaster. Especially in sectors like chemical, manufacturing and logistics, that require continuous human alertness to remain safe, while working. That’s why it becomes imperative that workers employed in these areas remain attentive to the changes happening in the workplace. However, human vision is liable to overlook small changes around them. And these small changes can give rise to potential disasters, risking human lives.

According to a report by the International Labour Organization, work-related injuries and deaths have accounted to US$3 trillion globally, which is the approximate GDP of India. Such situations can be mitigated by deploying an AI-powered solution, which can identify the imposing threat to human life, and can create a safer workplace. With the help of Artificial Intelligence, the pattern associated with threats to human life can be identified, as well as human injuries could be prevented.

Thus, in a set-up that demands, rigorous work by humans, utilization of tools and equipment, and sectors involved with fireworks, the AI-based solution would be helpful for providing insights, about the organizational set-up, so that these hazards can be prevented. Also, these AI-powered solution does not require an infrastructure overhaul, but can be incorporated in the existing security system.



The CCTV camera that is used for monitoring the workplace especially warehouses, only reports the accident or hazardous situation, once that event has already happened. An AI-based solution, powered by deep learning, can be hence installed in the CCTV camera, for achieving zero accidents in the manufacturing premises. An AI-powered solution can provide a virtual map to analyse the total operational area, marking hazardous areas, defining non-compliance areas and configuring the different types of alerts, in case the disaster happens. These alerts can range from sending SMS and mail to the announcement through buzzers.

In this way, the authorities can be notified, by real time-notifications, in situations where compliance is compromised. This will help the enterprises in countering the existing problem of disaster at workplace.


Fire Detection

The traditional fire alarms installed in buildings and workplaces are integrated with smoke and thermal detectors, which takes a lot of time, for notifying about the disaster. Any traditional fire alarm responds after five minutes, once it detects the fire. This means that a potential threat of fire spreading gets accelerated. By incorporating the traditional fire alarms with AI-powered solution would help in an earlier notification of the fire hazard. The AI-based system also surveys the area to detect any ingrained loop-hole in the electrical connection, of the building or workplace.

With the help of an AI-based solution, the number of people present in the building, and the number exiting the building can also be identified, which guides the fire-fighters to identifying the correct floor, thus saving critical time.

An AI-powered solution also gives the exact location of the fire, and send alarms to the authorities.


MHE Safety

In any supply chain set-up, Material Handling Equipment Safety is integral for successful operations. The MHE includes transporting, controlling, storing, protecting and enumerating of products at any step in the supply-chain operation. Despite proper training to the employees, occurrence of an accident is inevitable.

Along with the employees, the pedestrians’ in the supply chain set-up are at risk of the potential hazard. By integrating an AI-based system in supply-chain operation, would help in creating a pathway for both the employees and pedestrians so that future hazards can be avoided. It can also identify the under-looked loophole, that might lead to disaster. By integrating the traditional MHE safety with AI, will help in identifying the hazard zones, so that enterprises can create an SOP which reduces accidents in those areas.



The Ergonomics is the process of designing or arranging workplaces, products and systems, so that people can use them. It is a branch of science that aims in understanding and learning human abilities and limitations, and then utilize this for improving people’s interaction with products, systems and environments.

However, a faulty pose while applying ergonomics can lead to potential physical damage. Back pain has been ruled out as one of the common workplace injuries. Thus to counter this, an AI-based solution, would help in monitoring the poses of employees and identifying the faulty pose. With the identification of the faulty pose, the risk of an injury is mitigated.

Thus, the concept of artificial intelligence does not always include as a disruptive technology, but it can also be utilized to provide solutions to existing human errors.


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