Case Studies

A leading beverage manufacturing facility needed a reliable way to prevent human entry into active machine zones during automated operations. High-risk areas such as palletization and stretch-wrapper zones required immediate intervention to eliminate accidents caused by unintended machine motion.

The Challenge

Automated packaging machines continue operating unless explicitly stopped, creating serious safety risks when operators enter machine zones. Existing safety processes relied heavily on manual lockout–tagout methods, which were prone to delays and human error.

Key challenges included:

• No real-time detection of human presence
• Risk of injury from unintended machine motion
• Manual safety protocols frequently bypassed
• Poor coordination between operator movement and machine logic

The SeeWise AI Solution

SeeWise deployed an AI-driven safety system using existing CCTV cameras and direct PLC integration to enforce real-time human–machine interlocks.

The solution enabled:

• AI-based detection of human presence in restricted zones
• Continuous monitoring of machine key signals
• Instant PLC signal writes to halt machine operation
• Automatic machine resume once the area is verified safe
• Centralized logging and monitoring through the SeeWise platform

How It Works

• Cameras monitor machine entry points and operator zones
• SeeWise AI detects human presence in active machine areas
• A real-time stop signal is sent directly to the PLC
• Machine motion halts immediately to prevent hazards
• Operations resume only after the zone is cleared

Impact

• 100% real-time machine safety automation on the shopfloor
• Prevention of machine operation during human presence
• Enforced strict human–machine interlock compliance
• Complete audit trail of entry and stop events

Business Value

• Reduced near-miss incidents and injury risk
• Improved SOP adherence and safety compliance
• Strengthened safety culture across shifts
• Minimized downtime caused by safety violations

An industrial metals manufacturer needed better visibility into furnace performance to control heat cycles, avoid overheating, and minimize wasted energy. Operators lacked real-time insight into idle vs active states and cycle efficiency.

The Challenge

• No real-time view of furnace status and utilization
• Difficulty correlating energy consumption with production output
• Manual logging of heat cycles and parameters
• Unplanned downtime due to inconsistent furnace behavior

The SeeWise AI Solution

SeeWise deployed an AI-based furnace monitoring system connected to existing cameras and signals. The system tracks every heat cycle, identifies idle time, and correlates operating states with energy use and production.

Key capabilities:

• Automated tracking of furnace active, idle, and anomaly states
• Visualization of heat cycle duration and deviations
• Alerts on abnormal patterns and extended idle states
• Dashboards for shift-wise and daily performance

Impact

• 5% reduction in furnace-related downtime
• 3–4% reduction in power usage
• Higher predictability of furnace performance

Business Value

• Lower energy costs per ton produced
• Improved planning for maintenance and production
• Better visibility for operations and management teams

A large manufacturing plant with multiple loading bays struggled to track truck arrivals, loading times, and yard congestion. Manual logging and radio communication led to delays and limited visibility for planning.

The Challenge

• No central view of which trucks are at gates, bays, or waiting
• Unclear loading and turnaround times per vehicle
• Manual coordination across security, operations, and dispatch
• Frequent yard congestion and demurrage risk

The SeeWise AI Solution

SeeWise used existing yard and gate cameras to automatically detect trucks, track their movement, and calculate dwell time at each stage of the process.

Key capabilities:

• Automatic detection of trucks at entry, bay, and exit
• Real-time status of each vehicle (waiting, loading, completed)
• Analytics on average loading times and bottlenecks
• Alerts for trucks exceeding allowed waiting or loading time

Impact

• Improved yard throughput and loading efficiency
• Reduced manual tracking and follow-up calls
• Earlier detection of bottlenecks and delays

Business Value

• Lower demurrage risk and penalties
• Better SLA adherence with logistics partners
• More predictable shipping and dispatch planning

An automotive components manufacturer wanted to strengthen PPE adherence and on-floor safety without relying only on manual supervision. Safety teams needed better visibility into compliance across shifts and zones.

The Challenge

• Inconsistent PPE usage across different shifts and contractors
• Manual audits that captured only a small sample of real activity
• Limited traceability for repeated non-compliance incidents
• Difficulty measuring effectiveness of safety training

The SeeWise AI Solution

SeeWise deployed a PPE detection solution using existing CCTV cameras across critical shopfloor zones. The system automatically identifies workers and checks for required PPE like helmets, jackets, and shoes.

Key capabilities:

• Real-time detection of PPE compliance vs non-compliance
• Zone-wise and shift-wise compliance dashboards
• Alerts for repeated violations in sensitive areas
• Historical trend analysis for safety KPIs

Impact

• Higher PPE adherence across operators and contractors
• Early identification of risky zones and behaviors
• More targeted safety interventions and training

Business Value

• Reduced incident risk and near-miss events
• Stronger safety culture and compliance reporting
• Better readiness for customer and regulatory audits