Intelligent hazard zone monitoring system
Background and business need
A plant producing personal protective equipment and the PSD warehouse are both highly dynamic spaces. Manual handling work runs here alongside heavy forklift traffic. The main traffic routes were already properly protected, but a safety review identified critical areas at the high-bay racking. Restricted sightlines, high storage levels and a fast work rate created the risk of a worker stepping into the path of a maneuvering forklift, or of a load shifting out of control. The client needed a system that would detect every hazard and flag the risk before an accident happened.
Project goals
The aim was a system that reliably recognizes workers and forklifts inside tightly defined hazard zones at the racking, covers ten warehouse workstations, removes blind spots, and gives clear visual information to operators and to people moving around the warehouse on foot.
The solution
TSafety designed an intelligent monitoring system built on real-time image analysis and deep neural networks. The cameras were installed and calibrated for full coverage of the areas under watch, and the detection algorithms were tuned to the conditions of this production environment. Several cameras are analyzed at once, which removes errors caused by obstruction and changing perspective. Video from eight cameras was processed on two compute units at 20 frames per second, keeping the system fast and dependable.
Each camera was given precise virtual hazard zones 1.5 meters wide around the racking, with any breach identified to within 50 centimeters. The system merges information from several viewpoints to reach one unambiguous alarm decision for a given workstation. LED signals visible from a distance show immediately whether a work position is clear or blocked.
Testing and results
After commissioning, the system ran two weeks of live testing at full production load. It eliminated every case of a worker entering the unloading zone while a forklift was working. Hazards were identified instantly, allowing machinery to be stopped before a situation turned dangerous. Safety improved with no cost to the pace of logistics operations. Our client gained real protection for its people, lower downtime risk and better health-and-safety standards.
Benefits
Safety rose sharply in one of the most demanding areas of the warehouse. The installation required no changes to existing infrastructure, and the architecture makes it straightforward to extend coverage to further work zones. With hazards identified automatically, employees work in a more predictable, better-ordered environment, which supports safety culture and operational efficiency alike.
Why TSafety
TSafety delivered a system grounded in field experience and in technology matched to how a production plant actually runs. The scope covered risk analysis, system design, hardware selection, algorithm development, installation and support in service. The result meets health-and-safety requirements and also creates a business advantage — safety is built into the logic of the process instead of slowing it down.
Book a consultation
Every day you wait is another chance for an accident or a costly shutdown. TSafety helps you protect your people, your equipment and your margins – and the first step is easy.
Call or write today. We will set up a free consultation and show you how our systems can raise the safety standard across your facility.
Do not wait for an accident to happen – act now.