Case Study

Augmenting Plant Monitoring and Road Safety with AI ​

Automating Safety Systems and Real-time Alerts​
Automated safety systems in industrial plants
%

Reduction in safety compliance issues​

%

Reduced traffic-related delays​

acres of coverage for safety monitoring​

Background

A major chemical manufacturer faced challenges in maintaining high safety standards across their vast plant operations, which span over 33,000 acres with extensive road networks. Traditionally reliant on manual plant monitoring, the company found this approach increasingly inefficient to meet stringent international safety ratings.The vast plant required advanced manufacturing industry safety solutions to handle the heavy truck traffic and complex operations. ​

As a part of their digital transformation journey, the client integrated Tata Elxsi's AI-powered monitoring system, addressing human monitoring limitations and enhancing overall plant safety and productivity in the manufacturing industry. ​

Challenge

​The client faced challenges in enhancing plant monitoring and safety, including accurate vehicle speed tracking, effective blind spot traffic monitoring, and ensuring driver compliance with seat belts and mobile phone usage. ​

Detecting illegal overtaking and raised dumper boxes to prevent collisions were critical measures within the safety monitoring system. Preventing jaywalking by keeping pedestrians within designated areas was also essential. Additionally, seamlessly integrating AI-powered monitoring solutions into existing workflows was crucial for real-time data monitoring and overall operational efficiency.

Solution

To address the client's challenges, Tata Elxsi implemented a comprehensive AI-powered monitoring solution, enhancing Plant monitoring and road safety, comprising:​

  • Specialised Cameras: Radar-enabled for speed and traffic monitoring.​
  • AI Algorithms: Real-time analysis of vehicle movements and safety compliance.​
  • Automated Traffic Signals: Adjusted based on real-time traffic flow data.​
  • Monitor Safety Compliance: AI systems to detect seat belt usage and cell phone distractions. ​
  • Overtaking and Jaywalking Detection: Real-time alerts for illegal overtaking and pedestrian violations.​
  • Dumper Box Monitoring: Alarm systems to notify raised dumper boxes near underpasses to prevent collision.
Radar-enabled specialised cameras for speed and traffic monitoring
Real-time AI alerts for road safety
Elimination of accidents at blind spots

Impact

The implementation of Tata Elxsi's AI-powered monitoring solution for Plant monitoring significantly enhanced safety and operational efficiency at for the chemical manufacturing company. Some key achievements included:​

  • Safety Compliance: Detected over 200 daily jaywalking violations and raised alerts, reducing safety compliance issues by 70%.​
  • Operational Efficiency: Real-time traffic monitoring reduced traffic-related delays by 30% and effectively eliminated accidents at blind spots​
  • Accuracy rate: Achieved a 95 % accuracy rate in detection of seat belt usage and cell phone distraction.​
  • Incident Prevention: Prevented major accidents involving raised dumper boxes, enhancing overall plant safety.​

Tata Elxsi's expertise and innovative approach in addressing complex safety challenges through advanced AI technologies, significantly helped the client improve overall safety and efficiency.

Services rendered

Tata Elxsi

  • Market Research​
  • Hardware Procurement and Support​
  • AI Model Development​
  • Software Development​
  • Verification and Validation​
  • Field Testing​
  • Platform Delivery and Real-Time Monitoring​

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