Robot cells and press lines are fenced, but workers step inside for a few seconds to clear a jam - exactly the moment the interlock was designed to prevent.
PPE and zone protection across a 45-camera auto-parts plant
A tier-1 automotive supplier deployed XCORE-16 boxes to enforce helmet and vest rules and keep workers out of robot cells, replacing manual patrols.
Automotive Manufacturing45 cameras · 2 production halls · 3 shifts
At a glance
Project snapshot
The essentials at a glance.
| Industry | Automotive Manufacturing |
| Scale | 45 cameras · 2 production halls · 3 shifts |
| Hardware | XCORE-16, XCAN VMS / Cloud |
| Key algorithms | Safety Helmet Detection, Reflective Vest Detection, Restricted Zone Intrusion, Machine Guarding Check |
Challenge
The challenge
What the site was dealing with before deployment.
PPE rules were enforced by two safety officers across a three-shift rota, which covers only a fraction of the floor at any given moment.
Solution
What we deployed
The configuration and how it was rolled out.
- Sixteen existing cameras re-pointed at cell entrances, walkways and the press line, connected over the plant VLAN to an XCORE-16 appliance.
- Virtual restricted zones drawn around every robot cell, with a pre-warning line 1.5 m before the physical fence.
- Helmet and vest rules applied to all production channels, with a relay output wired to the zone warning beacon.
- Events pushed to the plant safety dashboard; a monthly violation report grouped by shift and by subcontractor.
Outcome
Results
Measured outcomes after go-live.
- Violations fell 72% in the first quarter and held at that level.
- No additional patrol staff were required; the safety team moved from watching to investigating.
- Every reported incident now carries an attached clip, cutting investigation time from days to hours.
Solutions
Solutions used in this project
Industrial Safety
Smart Factory Safety & Efficiency
Machine-zone protection, PPE compliance and production-area monitoring that plugs into an existing plant CCTV system.
View solutionSecurity & Community
AI Perimeter Intrusion Protection
Replace false-alarm-prone motion detection with AI intrusion analysis along fences, walls and open boundaries.
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