Top 5 Use Cases of Computer Vision in Manufacturing

The manufacturing industry has changed drastically in the last decade with the advent of Industry 4.0. The concept introduces industry to smart manufacturing that uses real-time data to increase efficiency, productivity and safety. The ability to innovate and meet global challenges has increased more than ever before.

Driving this change is computer vision—a technology that uses artificial intelligence (AI) to enhance various aspects of manufacturing. From ensuring worker safety to optimizing vehicle operations and improving product quality, it is setting new standards in setting up smart factories all around.

viActa pioneer in AI-powered solutions is revolutionizing the manufacturing sector with its innovative technology. With a constant focus on using the latest AI methods to improve the work environment, a number of modules have been created to meet the needs of the sector.

There is a growing concern for the safety of workers in the manufacturing sector. With an estimated cost of work injuries and illnesses ranging from $176 billion to $352 billion Annually, manufacturers are constantly at risk of escalating incidents in the workplace that cause human and resource losses.

One of the challenges that increase security risks in the sector is the reliance on manual surveillance processes. Can do with the use of power tool by AI Automated incident analysis and reporting that can prevent accidents in real time.

Imagine a A steel manufacturing facility where welding equipment is being operated to fabricate structures. Workers are exposed to hazards including burns, eye injury from intense light, and inhalation of hazardous fumes.

With viAct's AI-powered security monitoring system, the following precautions are immediately identified.

Technology enabled monitoring allows detection of similar incidents in different manufacturing units and prevents accidents to a large extent. The use of technology reduces direct human interaction in and around dangerous machinery on the factory floor which directly affects the level of safety.

From ensuring the mandatory use of safety equipment such as helmets and gloves to identifying potential violations on the worksite, technology is used to track workers' movements and protect them from workplace accidents. Uses the system.

Manufacturing facilities include a large number of mobile plants that operate in close proximity to workers and vehicles. According to OSHAForklifts are the cause of a significant number of workplace accidents. To spread awareness about the safe use of forklifts, National Forklift Safety Day A forklift event is celebrated by the UK Material Handling Association to focus on the 7 stages of the cycle.

Computer vision technology involves the use of video analytics to define forklift high-risk areas and manage them with zero blind spots. While Forklift monitoring systems Allow digitized tracking, here's how they can manage common tasks effectively.

1. Closely monitor operator behavior e.g Detect distractionsNot wearing seat belts or required PPE, and engaging in unsafe activities such as using mobile phones or smoking.

2. Manage balanced loading and unloading using AI-powered sensors and computer vision help with accurate positioning and handling, minimizing damage to goods.

3. Avoid collisions using Automated fleet tracking With real-time GPS tagging of vehicles.

4. Ensuring pedestrian safety on the factory floor by reporting proximity, abnormal traffic congestion, forward collision warning, automatic speed control, and blind spot avoidance.

5. Using AI algorithms to analyze the facility layout and current forklift location to determine the most efficient routes, reducing travel time and fuel consumption.

viMAC is an AI-based monitoring device that uses AI processors in IP cameras to detect collisions around forklifts especially when other mobile vehicles are involved. With the ability to cover 6M horizontally and 5M vertically, its installation on a vehicle can also provide 900 downward visibility. It is effective in –

• Identification of lifting objects

• Tracking Machinery Operation

• Detecting operator distraction

• Detection of danger zones

• Intrusion detection

The common operational areas of manufacturing with forklifts along with other vehicles in the picture can be easily controlled by the integration of such smart tools facilitated by AI.

From detecting humans working near vehicles to avoiding collisions with other mobile plants such as pallet jacks, cranes and elevated platforms, forklift operations have gained a lot of control with technology.

The most important output from any manufacturing facility is product quality. The use of computer vision serves as an active tool to ensure excellent product quality. In the automotive industry, it is widely used to detect irregularities such as misalignment, foreign objects, and surface defects.

The textile industry uses it primarily to inspect fabrics for defects such as tears, stains, and color inconsistencies. Even in agriculture, the above technology is used in grading and sorting of fruits and vegetables.

In these areas, viAct's AI-powered video analytics primarily includes providing –

gave AI powered security monitoring system Helps detect defects in manufactured goods at an early stage. It helps reduce unplanned downtime by identifying obstructions around machines, conveyor belts, or surroundings.

Automatic alerts from video feeds of empty shelves or containers to restock resources help avoid a single second of idle time. Product counts in assembly lines are always recorded in the database for any time investigation.

Manufacturers are under constant pressure to comply with strict environmental health and safety (EHS) standards, which aim to protect workers, the environment and the community. With the advent of modern technologies, especially computer vision, the task of maintaining compliance has become more manageable and efficient.

According to US Bureau of Labor Statistics2.8 million incidents of injury and illness are reported by employers in the year 2022. This represents a 7.5 percent increase over 2021. There are several areas of concern when it comes to occupational diseases that occur among workers due to the nature of work.

How can the most common forms of occupational diseases caused by musculoskeletal disorders be prevented using such technology? Ergonomic assessment using REBA and RULA Digital EHSS Monitoring System Facilitate automatic monitoring of worker postures, hours spent without movement, and detection of signs of impairment.

Workers involved in packaging work in a manufacturing facility spend many hours in this position. viAct's AI-powered video analytics uses their diagnostics to detect –

• Use the NIOSH lifting equation for manual lifting tasks.

• Estimate joint angles for quick identification.

• Instant alert to correct currency.

• Create an overall score for periodic evaluation.

• Recommend personalized optimization ideas from collected data.

In addition to health and safety, this system serves as a resource. Environmental monitoring Along with this, it is continuously engaged in monitoring emissions, waste disposal and water quality. AI's role in improving ESG scores can be effective as it helps improve waste management by around 70 percent. Additionally, lean manufacturing principles to eliminate waste for overall process improvement can be substantially achieved with this technology.

Accurate record keeping and regular audits are essential components of an effective safety management system. For example, i Food and Beverage IndustryMaintaining hygiene and safety is very important. Use of technology to provide detailed reports on hygiene standards and generate alerts for any deviations.

The provision of viAct significantly improves these processes by automating data collection, analysis and reporting. They ensure that safety protocols are followed, provide evidence of compliance, and help identify areas for improvement.

AI-powered security monitoring is a structured way to use the collected data.

Step 1 – Automated data collection – includes footage of worker activities, machinery operations, and environmental conditions.

Step 2 – Real-time analysis and alerts – Instant alerts are generated to notify deviations.

Step 3 – Detailed Reporting – Generates detailed reports on various safety metrics, such as PPE compliance rates, incident events including slips, trips and falls, and machinery performance in its intuitive dashboard. viHUB.

Step 4 – Auditing – Data can be stored in the cloud using an RTSP link for a desired period of time and auditors can visually review data, analyze trends, and assess the effectiveness of security protocols.

The storage of large amounts of data allows the system to recognize patterns and suggest corrective actions in the future. This leads to an all-in-one supervisor who guides the factory floor without human intervention at all times.

viAct's computer vision technology is transforming the manufacturing sector by providing innovative solutions for quality control, safety, equipment monitoring, and environmental monitoring. As manufacturers continue to embrace Industry 4.0 and lean manufacturing principles, adopting advanced technologies like viAct will be critical in maintaining competitiveness, increasing efficiency and ensuring safety in manufacturing operations.

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