How a Steel Manufacturer Recovered $380,000+ and Achieved Its First Injury-Free Quarter in 18 Months
The Challenge
A leading steel manufacturer operated a large-scale plant with CCTV cameras across their floor — but no active monitoring capability. Production had dipped 12% on night shifts with no clear cause. PPE compliance was managed through monthly spot checks. Supervisors were manually reviewing dozens of camera feeds and spending 4+ hours per shift on footage review instead of floor management.
What VivyaSense Found — First 30 Days
- 1
Workers averaging 23 minutes of untracked break time per shift — invisible to management until camera analytics surfaced the pattern.
- 2
3 machine stations idling 40+ minutes per shift due to material supply delays clearly visible on camera — but never correlated to production output until VivyaSense connected the data.
- 3
14 PPE violations per shift going uncorrected — including workers in crane zones without required safety observers. A direct OSHA Willful violation risk worth up to $156,000 per citation.
Results — 90 Days
- ✓
2.1% production time recovered → Estimated annual value: $280,000+
- ✓
65% reduction in PPE violations → OSHA fine risk reduced by an estimated $100,000/year
- ✓
Zero recordable injuries in 90-day monitoring period → First clean quarter in 18 months
- ✓
Shift supervisors reduced manual camera review from 4 hours/shift → under 20 minutes → Attention redirected to floor operations
ROI Summary
“We had cameras everywhere and still had no idea what was actually happening on the floor at 2am. VivyaSense told us things about our own plant we'd never been able to see before.”— HSE Manager, Steel Manufacturing Plant