Unplanned downtime is a killer for any manufacturer. It disrupts productivity and reduces profitability. In worst case scenarios, it can negatively impact brand reputation, total product availability or product availability timelines.
According to the International Society of Automation, unplanned downtime can cost manufacturing plants between 5–20% of their annual productivity.
For critical plant equipment – like broaching, drilling, laser cutting and welding machines, or conveyor belts -- AI radiometric thermal cameras can ensure safe operating temperature limits are not exceeded. Temperature changes are often the earliest warning sign of current or future equipment problems. If overheating occurs, production supervisors are immediately alerted and can use the insights to perform the necessary preventive maintenance tasks before a more costly breakdown occurs, potentially leading to unplanned downtime.
This information can help maintenance professionals determine optimal proactive equipment maintenance procedures: when to schedule component and system checks, number of operation hours between fluid interval changes (lubricants, greases), and more.
A Safer Factory Floor
Properly positioned AI surveillance cameras enable manufacturers to identify real-time workplace hazards such as slip-and-fall incidents, improper lifting of heavy materials, poor handling of hazardous materials, or employees neglecting to wear Personal Protective Equipment (PPE).
Another key area where safety can be improved with the right AI video surveillance solutions is improper or unsafe forklift operations, which is one of the leading causes of workplace injuries and death.In many countries, it’s estimated that forklifts are involved in more than 5% of workplace-related serious injuries and more than 10% of workplace-related deaths.
Intelligent surveillance cameras are increasingly incorporating sophisticated and precise AI applications. This type of integrated solution can help manufacturing facilities better protect employees, and dramatically reduce forklift-caused accidents, compliance infractions, and costly legal expenses.
Hanwha Vision’s Smart Factory solution combines proven video surveillance technologies with proprietary software and AI analytics to monitor every part of a forklift’s operations.
If drivers exceed pre-designated safe forklift speed limits, they receive an instant notification and warning to slow down. These alerts are logged and sent to security professionals who are monitoring the factory or plant floor either onsite, or from a remote location, enabling them to always have immediate access to this important safety information.
When a forklift is parked in the wrong location, similar alarms will be triggered. Also, valuable Proximity Detection notifications ensure that there is always a safe distance maintained between a person and a forklift, between multiple forklifts, or a forklift and a piece of equipment or structure, like tall columned shelving stacks.
Improved Compliance & Reporting
Maintaining and reporting on compliance with crucial maintenance, operating, and sustainability-related regulations, is essential for successful manufacturing facilities. However, it’s often a time-consuming process.
By providing detailed logs and reports of monitored environments, AI-driven surveillance systems can help companies enhance their compliance efforts and simplify compliance reporting efforts. Real-time alerts help document every access attempt or unsafe action, like personnel not wearing proper PPE.
Automated reports, with this level of transparency and accountability, enable manufacturers to accurately assess their team’s overall compliance with industry and safety regulations, and reduce time and money spent on compliance reporting efforts. They can also help validate the effectiveness of current training efforts or identify areas that require further employee training to maintain safe operating procedures.
Simplifying Parcel Shipping & Tracking Logistics
We all know that shipping and delivery errors occur for many reasons. Packages can be lost, damaged, delayed, or stolen. They may be addressed to the wrong customer or packed with incorrect and/or missing items. There are new options available to help manufacturing facilities support advanced logistics automation, integration, and reporting.
These integrated AI-powered surveillance solutions cover every part of inbound and outbound package delivery, including receiving, handling, shipping, and tracking. They quickly match videos with work history, enabling operators to respond effectively to customer claims for errors, omissions, or damage throughout the packing process.
For example, Hanwha Vision’s dual-sensor Barcode Reader Camera combines barcode recognition, video capture, parcel tracking, and logistics management all in a single AI-powered device. The camera’s integrated search and image-based tracking software delivers accurate and faster recognition. It’s single-system design lowers installation and maintenance costs compared to conventional systems with separate BCR and CCTV devices. Hanwha Vision’s Logistic Tracking Software communicates with logistics centers’ barcode reading systems to facilitate product and tracking inquiries.
For manufacturers, making every second count is essential. Lost productivity kills profitability. Poor safety practices and outdated security technologies invite danger in the form of intruders and bad actors who may steal your valuable equipment, pose threats to employee safety, and/or disrupt your operations in other unforeseen ways.
By investing in the right AI-enabled video surveillance solutions, manufacturers can take major leaps toward improving plant floor productivity, limiting unplanned downtime, workplace safety, compliance reporting, and supply chain efficiency.
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