AI-powered factory safety monitoring
for Indian manufacturers
A camera-based safety system that detects PPE violations, restricted zone intrusions, fire, smoke, and spills in real time. Alerts reach supervisors within seconds. Every violation is logged with video evidence for EHS audits and DISH compliance.
Safety Dashboard
12 zones activeWhat you are dealing with today.
Safety officers cannot watch every zone at once
A factory with 400 workers and 15 zones cannot be monitored by 2-3 safety officers. Violations in far corners of the shop floor go unnoticed until an incident occurs.
Incidents are discovered after the fact
Without real-time monitoring, a worker entering a hazardous zone without PPE or a chemical spill near a walkway is only discovered when someone gets hurt. Reactive safety is expensive.
Compliance documentation is manual and incomplete
Safety logs are maintained on paper. Violation records depend on what safety officers personally witness. Auditors from DISH, factory inspectorate, or ISO auditors find gaps every time.
From setup to results.
Install cameras at critical safety zones
Position cameras at entry points, machinery zones, chemical storage areas, and high-traffic walkways. The system works with your existing CCTV cameras or new cameras we supply.
Camera Zones
Add Camera| Camera | Zone | Coverage | Status |
|---|---|---|---|
| CAM-01 | Assembly Line A | 180° | Online |
| CAM-02 | Welding Bay | 120° | Online |
| CAM-03 | Loading Dock | 360° | Online |
| CAM-04 | Chemical Store | 90° | Online |
Configure safety rules for each zone
Define what to detect in each zone: hard hat compliance, safety vest detection, restricted area intrusion, forklift proximity, fire, or smoke. Draw zones and set sensitivity through the dashboard.
Zone Rules
12 rules activeHelmet + vest + boots in all zones
No entry without clearance badge
Smoke + flame trigger instant alarm
Alert if person within 3m of forklift
AI monitors every zone in real time
The system analyses camera feeds continuously. When a violation is detected, an alert with a screenshot is sent to supervisors via SMS, WhatsApp, or the PA system within 5 seconds.
Real-Time Monitor
24 camerasViolations are logged for audits and trend analysis
Every detection is stored with timestamp, zone, violation type, and screenshot. Generate daily, weekly, and monthly safety reports. Track trends to identify repeat offenders and high-risk zones.
Audit Trail
Export| Time | Zone | Type | Severity | Evidence |
|---|---|---|---|---|
| 10:42 | Welding Bay | No helmet | High | Screenshot saved |
| 09:15 | Loading Dock | No vest | Medium | Screenshot saved |
| 08:30 | Chemical Store | Unauthorised entry | High | Video clip saved |
What you get.
PPE compliance detection
Detects hard hats, safety vests, safety goggles, gloves, and safety shoes in real time. Works accurately in varied lighting, including low-light conditions common in factory interiors.
PPE Compliance
Restricted zone intrusion alerts
Draw virtual boundaries around hazardous zones, machinery exclusion areas, or chemical storage. The system alerts when unauthorised personnel enter. Works with or without access control integration.
Restricted Zones
| Zone | Access Level | Violations (30d) |
|---|---|---|
| Chemical Store | Level 3 only | 0 |
| HV Panel Room | Electricians only | 1 |
| Server Room | IT + Admin | 0 |
Fire, smoke, and spill detection
Visual detection of fire, smoke, and liquid spills on the factory floor. Triggers alerts faster than traditional smoke detectors in large open factory spaces where conventional sensors are less effective.
Environmental Alerts
MonitoringForklift and vehicle proximity warnings
Detects when pedestrians are too close to forklifts, cranes, or moving vehicles. Alerts operators and supervisors before a collision occurs.
Forklift Safety
Safety analytics and trend reporting
Track violations by zone, shift, worker density, and time of day. Identify patterns that indicate systemic safety gaps. Generate reports formatted for DISH inspections and ISO 45001 audits.
Trend Report
Video evidence for every violation
Each alert includes a timestamped screenshot and 10-second video clip. Evidence is stored locally and cannot be tampered with. Useful for incident investigations and insurance claims.
Evidence Library
| Incident | Zone | Date | Evidence |
|---|---|---|---|
| No helmet | Welding | 24 Sep | Screenshot + 30s clip |
| Zone breach | Chemical | 23 Sep | Full video + alert log |
Watch a quick demo.
Factory Safety Detector in 60 seconds.
What it looks like in practice.
Textile mill, Tirupur
A textile mill with over 400 workers across dyeing, weaving, and finishing sections was averaging 12 safety incidents per quarter. Two safety officers could not physically monitor all zones. PPE compliance was inconsistent, especially during night shifts. DISH inspections repeatedly flagged documentation gaps.
After deploying Factory Safety Detectors across 6 critical zones, safety incidents dropped from 12 per quarter to fewer than 3. Real-time violation alerts ensured supervisors responded within minutes. The next DISH inspection was cleared with zero observations.
"Before this system, our safety reports were based on what we happened to see during walkabouts. Now every violation is recorded automatically with a photo and timestamp. Our incident rate has dropped and our audit readiness has improved dramatically."Arun S., EHS Manager, Textile Mill
Works with your existing tools.
Enterprise-ready from day one.
Deployment
- Works with existing CCTV cameras or new installations
- Edge processing unit installed on-site
- Supports up to 16 camera feeds per zone unit
- Wired ethernet connectivity
- Multiple units for multi-zone coverage
Security and compliance
- All video processing happens on-premise
- Violation evidence stored locally with encryption
- Role-based dashboard access for EHS teams
- Audit trail for all alert acknowledgements
- Reports formatted for DISH and ISO 45001 audits
Clear pricing. No surprises.
Pricing depends on your team size, deployment, and support needs.
Plus ₹18,000/month monitoring subscription per zone. GST extra.
INCLUDES
- Edge processing unit for one zone (up to 16 cameras)
- Pre-loaded safety detection models
- Real-time alert configuration
- Safety analytics dashboard
- Installation and camera integration
- First-year hardware warranty
Built for specific needs.
Good fit
- Textile mills, steel plants, and chemical factories with large workforces
- Automobile and auto-parts manufacturing units
- Warehouses and logistics hubs with forklift traffic
- Construction sites needing PPE and zone compliance
- Any factory preparing for ISO 45001 or facing DISH scrutiny
Not designed for
- Small workshops with fewer than 20 workers (manual supervision is more practical)
- Office environments without physical safety hazards
- Factories looking only for attendance tracking (a biometric system is more appropriate)
- Sites without existing CCTV infrastructure and no budget for cameras
How much does the Factory Safety Detector cost?+
Pricing starts at ₹4,20,000 per zone as a one-time hardware cost, plus ₹18,000 per month per zone for the monitoring subscription. Each zone supports up to 16 cameras. GST is additional.
How many cameras does one zone unit support?+
Each zone unit handles up to 16 camera feeds. Most factory zones need 4-8 cameras for comprehensive coverage. Larger factories deploy multiple zone units.
Does it work with our existing CCTV cameras?+
Yes. The system works with any IP camera supporting ONVIF or RTSP, including Hikvision, Dahua, and CP Plus. We assess your existing cameras during the site survey.
How fast are the alerts?+
From detection to alert delivery, the typical latency is under 5 seconds. Alerts go via SMS, WhatsApp, email, or integration with your PA/siren system.
Can it detect custom safety rules?+
Yes. Beyond standard PPE and intrusion detection, we can train custom models for specific hazards relevant to your factory. Examples include open machine guards, missing safety barriers, or improper stacking.
Does it help with DISH compliance?+
The system generates violation reports with timestamps and evidence, which can be presented during Directorate of Industrial Safety and Health inspections. It does not replace your EHS team but gives them complete, verifiable data.
What happens if the internet goes down?+
All processing and alerting happens on-premise. Alerts are delivered over your local network. SMS and WhatsApp alerts require internet, but the PA/siren integration works without it.
Can workers be identified in violation screenshots?+
The system captures zone-level violations with screenshots. Individual face identification is available as an optional module but requires consent and compliance with applicable privacy regulations.
Related guides.
Making existing cameras intelligent with AI
Add AI analytics to existing CCTV without camera replacement.
Read the guideAI for construction site tracking and compliance
How AI monitors safety compliance on construction sites.
Read the guideOn-premise vs cloud AI
When to keep AI processing on-site instead of the cloud.
Read the guideFactory Safety Detector.
Let's set it up.
Book a 20-minute demo, get a quote, or just ask a question.
Our team in Chennai responds within one working day.