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ManufacturingAIIoT

Sentinel Vision — AI Safety Copilot for Factories

Existing CCTV cameras become 140 tireless safety officers that predict accidents before they happen.

Client
An automotive components manufacturer with 3 plants
Industry
Manufacturing
Year
2026
Timeline
6 months
Sentinel Vision dashboard and mobile app
140cameras made intelligent
62%fewer recordable incidents
<200 msdetection-to-alert
0footage leaves the plant
Overview

Sentinel Vision runs computer-vision models on edge devices connected to a plant's existing CCTV. It detects missing PPE, people in forklift paths, blocked fire exits and unsafe postures in real time — and, uniquely, learns near-miss patterns to predict where the next incident is most likely.

The challenge

Safety teams could review only a fraction of camera footage, incidents were reported after the fact, and near-misses — the best early warning signal — went almost entirely unrecorded.

Our solution

We deployed edge AI boxes that process video locally (no footage leaves the plant), a privacy layer that blurs faces by default, and a central dashboard that turns detections into heatmaps, risk scores per zone and automatic WhatsApp alerts to shift supervisors.

Inside the platform

Key capabilities

01Real-time Detection

  • Helmet, vest, glove & goggle compliance
  • Person–forklift proximity & speed zones
  • Blocked exits, spills and smoke
  • Ergonomic posture risk scoring

02Predictive Safety

  • Near-miss clustering & trend detection
  • Zone risk forecast for each shift
  • Root-cause suggestions using a safety LLM
  • Weekly auto-generated safety briefings

03Privacy & Operations

  • On-prem edge processing
  • Face blurring by default
  • WhatsApp / siren / PA integrations
  • Works with existing IP cameras
Gallery

Screens & experiences

Technology stack

YOLONVIDIA JetsonDeepStreamPythonFastAPIReactGrafana

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