Computer Vision AI Transforms Industrial Safety with PPE Detection & Geo-Fencing

A leading automotive manufacturing company with multiple production facilities faced critical safety compliance challenges. Workers frequently entered hazardous zones without proper Personal Protective Equipment (PPE), leading to safety violations, potential accidents, and regulatory compliance issues. The company needed real-time monitoring across 15 production lines, 8 warehouses, and 3 assembly plants. Traditional manual safety inspections were inefficient, covering only 20% of work areas daily, and incident reporting was reactive rather than preventive. The company was losing $2.3M annually due to safety-related downtime, insurance claims, and regulatory fines.

Logic Clutch developed a comprehensive Computer Vision AI solution integrating advanced PPE detection with intelligent geo-fencing security systems. Our solution deployed 450+ high-resolution cameras across all facilities, powered by custom-trained deep learning models capable of detecting helmets, safety vests, gloves, safety glasses, and steel-toed boots with 98.7% accuracy. The geo-fencing system created virtual boundaries around hazardous areas including chemical storage zones, heavy machinery operations, and high-voltage electrical areas. Real-time alerts were sent to supervisors and workers via mobile apps, digital displays, and audio announcements. The system integrated with existing access control systems, automatically restricting entry to non-compliant personnel. Advanced analytics dashboards provided insights into safety patterns, compliance trends, and risk hotspots across all facilities.