Moving machinery and hot zones injure workers who step in for a second.
Smart Factory Safety & Efficiency
Machine-zone protection, PPE compliance and production-area monitoring that plugs into an existing plant CCTV system.
Smart FactoryIndustrial Safety
Pain points
The challenge
Sound familiar? These are the problems our customers bring to us every week.
PPE rules exist on paper but are not enforced on the floor.
Production lines stop for problems nobody saw early enough.
Solution overview
How this solution works
Machine-zone protection, PPE compliance and production-area monitoring that plugs into an existing plant CCTV system.
Every XCAN AI Box runs its algorithms on the edge, which means detection continues even when the network does not. Existing cameras are reused, alerts are verified with snapshots and clips, and all events land in one management console.
How it works
Deployment in four steps
From the cameras you already own to a fully monitored site - typically inside one week.
Protect machine zones
Virtual guards around presses, robots, conveyors and ovens.
Verify PPE at the zone
Helmet, vest, gloves and mask checks on entry to each area.
Supervise critical posts
Leave-post, sleeping-on-duty and phone-use detection for operational discipline.
Feed the control room
Events push to SCADA, MES or the plant dashboard through the Open API.
Algorithm library
AI algorithms used in this solution
Each algorithm can be enabled per channel, per schedule, with its own sensitivity and alarm rule.
Restricted Zone IntrusionMachine Guarding CheckSafety Helmet DetectionGlove & Hairnet DetectionLeave-Post DetectionSleeping on DutyPhone Usage DetectionFire / Smoke Detection
Hardware
Recommended hardware
Right-sized appliance and software for sites like this.
XCORE-16
Handles 16 cameras with per-channel algorithm profiles. Supports RAID-less dual storage, multi-user roles and open API push to third-party platforms.
View productXCORE-32
Built for parks, malls and construction groups. 32 AI channels, dual GbE uplink, 1+1 storage and optional redundant power for 24/7 mission-critical sites.
View productXCORE-64
For city-level and multi-site projects. Runs 40+ algorithms across 64 streams, acts as a cluster master and hosts the model training and management console.
View productBenefits
What you get
Outcomes our customers measure after deployment.
- Fewer machine-related injuries through constant zone protection.
- PPE compliance becomes a measured KPI instead of a reminder.
- Faster abnormality detection keeps lines running.
Use cases
Typical deployment scenarios
This solution is field-proven in the following environments.
Press and robot cellsConveyor linesOven / furnace areaAssembly line PPEControl room staffingWarehouse forklift lanesChemical store
FAQ
Frequently asked questions
Will it interfere with our production network?
No. The AI box can run on an isolated VLAN and only pushes events - no production traffic passes through it.
Can we detect whether a machine guard is open?
Yes, machine guarding check uses video to verify the guard, door or cover is in the correct position before operation.
Case studies
Where this is deployed
Recent projects built on this class of solution.
Automotive Manufacturing
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.
-72%safety violations / month
45cameras covered
Construction
Eight metro construction sites unified under one safety dashboard
A metro contractor rolled out 260 cameras on XCORE-32 appliances, combining PPE detection, danger-zone alarms and face-based labour attendance.
8sites unified
260cameras
Related solutions
Often deployed together with this solution.
Industrial Safety
Smart Construction Site Safety
PPE compliance, danger-zone control and worker attendance on every camera, with offline operation for remote sites.
View solutionIndustrial Safety
Power Plant & Substation Safety
Unattended substations, thermal power plants and new-energy sites monitored for intrusion, fire and operational discipline.
View solutionIndustrial Safety
Chemical Park Safety
Strict zone control, PPE enforcement and early fire/smoke detection for chemical plants and hazardous-material warehouses.
View solutionTell us your scene - we will design the solution for you.
Send us your site description, camera list and the risks you want to control. Our engineers will reply with a channel-by-channel algorithm plan and a recommended hardware configuration, free of charge.