Steel Plant Reduces PPE Violations by 67% Across 84 Cameras
The Challenge
An integrated steel plant in Jharkhand, India — 84 cameras spanning the blast furnace area, rolling mills, and raw material yards — monitored over 1,200 workers across 3 shifts. All cameras were passive recording only, with no real-time alerting. PPE non-compliance was rampant in extreme heat zones where workers routinely removed helmets and face shields. Multiple near-miss incidents went unreported. Manual safety audits covered less than 5% of the total floor area, leaving critical blind spots across the most hazardous operational zones.
What VivyaSense Found — First 30 Days
- 1
PPE non-compliance in blast furnace zones: 340+ violations per week — helmets removed due to extreme heat, face shields absent during slag tapping. Zero automated detection prior to deployment.
- 2
Unauthorized zone entries near rolling mills: 23 workers per shift entering restricted cooling areas without clearance — bypassing manual checkpoints during shift changeovers.
- 3
Near-miss events at raw material yards: 18 forklift-pedestrian close calls per week at ore stockpile intersections — none captured in existing incident logs.
- 4
Prolonged heat exposure in furnace-adjacent zones: 47 workers exceeding safe thermal exposure limits daily — no alerts, no rotation enforcement, no documentation.
Results — 12 Weeks
- ✓
PPE compliance in blast furnace zones improved from 41% to 93% — real-time helmet and face shield alerts reduced violations by 67% within 90 days
- ✓
Unauthorized rolling mill zone entries reduced by 89% — geo-fenced alerts triggered immediate supervisor response, eliminating shift-change bypass patterns
- ✓
Near-miss incident capture rate increased from <5% to 94% — automated detection at ore yard intersections enabled proactive route redesign
- ✓
Heat exposure violations reduced by 72% — automated rotation alerts ensured no worker exceeded thermal limits, supporting DGFASLI compliance documentation
ROI Summary
“We went from reviewing yesterday's footage to stopping today's violations in real time. In a blast furnace environment, that shift from reactive to proactive monitoring isn't just efficiency — it's the difference between a near-miss and a fatality.”— Plant Safety Director, Integrated Steel Plant, Jharkhand