Improving Safety Under Suspended Dies – A Successful Pilot at Renault Nissan

Factories are unique ecosystems. Massive machines move tons of metal with precision and power. Yet, in the middle of this carefully coordinated operation stands the most vulnerable element in the system: the human.

In environments like stamping shops, where large dies are lifted and moved using overhead cranes, even a small lapse in visibility or awareness can lead to serious safety risks. This challenge led us to explore how technology could help monitor and prevent unsafe situations on the shop floor

We recently completed a successful Pilot deployment for Safety Monitoring at Renault Nissan, in partnership with Twinzo and Green Futurz. The objective was clear, preventing accidents in one of the most high-risk areas of the plant - the stamping shop.

The Challenge - Risk Under the Lifted Die

In the stamping shop, large dies are stored and frequently moved using overhead cranes. These dies are extremely heavy. When lifted, they create an unsafe zone underneath and around them.

Even with strict safety protocols, operators may unknowingly enter the area below a suspended die. In such situations, even a small mistake can result in serious injury.

The safety team wanted a system that could,

• Monitor the area continuously
• Identify when a die is lifted
• Detect if a person enters the unsafe zone
• Trigger alerts before an incident occurs

The goal was prevention, not reaction.

The Solution - Monitoring from the Crane with Real-Time Alerts

To address this risk, a camera was strategically installed on the overhead crane. This provided a clear top view of the area below the lifted die.

When the die was lifted,

• The system identified the lifting activity
• A safety boundary was defined around the suspended die
• The distance between the die and nearby personnel was calculated
• If a person entered the unsafe zone, an alert was triggered immediately

This ensured that the system was directly connected to the actual lifting operation, not just general area monitoring.

Instead of depending only on human supervision, the area was continuously monitored with real-time alerts to prevent unsafe situations.

The Role of Twinzo and Green Futurz

This Pilot was strengthened through collaboration.

Twinzo enabled a digital twin of the shop floor, providing full operational visibility. Leaders and safety teams could see how operations were moving in real time, creating better transparency and control.

Green Futurz supported the RFID system to monitor forklift operations. This ensured safe tracking of material movement and vehicle activity within the plant.

Seewise enabled AI-based safety monitoring that activates when a die is lifted, creating a dynamic safety boundary around the suspended load.

Together, the combined solution provided,

• Visibility of operations
• Tracking of material movement
• Proactive human safety protection

This was not a single solution but an integrated safety approach.

The Impact

During the Pilot, the system successfully demonstrated,

• Real-time detection of unsafe proximity under suspended dies
• Immediate alerts when personnel entered unsafe proximity
• Increased operator awareness around suspended load safety
• Stronger control in high-risk zones

Most importantly, the plant moved from reactive safety to proactive prevention.

Why This Matters for Decision Makers

For plant heads and digital transformation leaders, safety and productivity go hand in hand.

This Pilot showed that,

• Safety can be improved without disturbing operations
• High-risk zones can be monitored continuously
• Real-time alerts reduce dependency on manual supervision
• Digital visibility improves accountability and control

The approach is practical, scalable, and aligned with modern manufacturing goals.

Moving Forward

Heavy lifting and material movement will always be part of manufacturing. The risk cannot be completely removed, but it can be managed effectively.

By combining digital visibility, movement tracking, and real-time safety monitoring, organizations can protect their people while strengthening operational control.

At Seewise, we believe safety should be built into daily operations, not reviewed only after incidents occur.