AI-Powered Safety Revolution: Computer Vision Surveillance for Chemical Manufacturing

@Faclon Team

November 14, 2025

2min read

About the Company

A leading multinational corporation founded in 1992, specializing in automotive solutions and manufacturing components for the automotive and transportation industries. With a commanding $7.3 billion market cap as of 2025, the company operates 74 manufacturing plants worldwide across 20 manufacturing units, employing over 6,000+ professionals across all business verticals. The organization focuses on innovation and cutting-edge manufacturing technologies to maintain its strong global market presence and competitive edge.

Problem Statement

Critical operational challenges threatening manufacturing efficiency

Personnel attentiveness issues Managing large-scale infrastructure with multiple CCTVs proved highly labor-intensive, leading to oversight of critical safety hazards and operational inefficiencies
Delayed response times Incidents like accidents, equipment malfunctions, and unauthorized access risked safety and led to unaccounted damages or security breaches
Evidence management complexity Enforcing daily compliance for security and safety while managing evidence effectively for reviews became a highly time-consuming activity
Specific operational risks Field operators neglecting safety gear in life-threatening environments, theft of precious materials, idle trucks creating bottlenecks, smartphone-distracted personnel, and unsafe forklift operations

How Faclon Solved the Problem

I/O Sense Platform: Comprehensive Industry 4.0 deployment for energy management and process optimization

No-code AI customization

Seamless AI model integration accessible without technical expertise, enabling rapid deployment and user-friendly operation

Multi-layered worker safety monitoring

PPE compliance detection for helmets, safety shoes, and vests; harness compliance at height; walking attentiveness and lane following detection

Advanced security features

Boundary intrusion detection, vehicle accident and near-miss detection, speed limit enforcement with penalty logging at exits

Operational optimization

Entry/exit timeline analysis for traffic flow optimization, vehicle dwell time monitoring, and bottleneck identification for loading/unloading bays

Intelligent system architecture

Existing CCTV integration, dedicated internet connection, real-time RTSP streaming with automatic incident notifications via SMS/email

The Outcome

Comprehensive results across operational efficiency

Safety compliance enhancement

PPE monitoring ensures consistent adherence to safety regulations, reducing workplace injuries and regulatory violations

Proactive accident prevention

Real-time accident and near-miss detection with immediate response capabilities ensuring safer operations

Behavioral improvements

Detection of inattentive walking in high-risk areas promotes safety culture, reducing related accidents and enhancing site-wide focus

Operational efficiency gains

Lane following and entry-exit analysis optimize vehicle traffic, reducing travel time and improving turn-around efficiency

Enhanced security posture

Boundary intrusion detection strengthens site security by proactively identifying and addressing potential security breaches

Behind the Scenes

Advanced technical implementation and strategic deployment considerations

Rapid model adaptation capability

Tagged images of new scenarios enable automatic model weight adjustments, accelerating development and deployment cycles

Continuous learning architecture

Models dynamically improve with added data, ensuring adaptability for diverse applications and upgraded use-cases

Cost-effective integration approach

Leveraged existing camera infrastructure without significant additional hardware investment, maximizing ROI

Network segregation strategy

Deployed on separate internet connection avoiding main IT network interference while ensuring secure data transmission

Comprehensive detection portfolio

10 distinct AI models covering worker safety (PPE, harness, attentiveness), vehicle monitoring (speed, accidents, dwell time), and security (boundary breaches, number plate detection)

Evidence management system

Automatic snapshot capture during incidents with designated personnel notifications, creating comprehensive audit trails for compliance and investigation purposes

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