A large manufacturing plant with over 3,000 workers across three production facilities was facing persistent safety compliance issues. Despite mandatory PPE policies, weekly audits consistently revealed that 15 to 20 percent of workers on the floor were not wearing required safety equipment at any given time. Manual spot checks were ineffective because workers would comply temporarily when supervisors were visible, then revert to non compliance once they moved on. The plant had recorded 23 safety incidents in the previous year, several resulting in lost work days.
Aptibit deployed Visylix with specialized PPE detection and safety gear AI models across all three production facilities. Over 200 cameras were configured to monitor critical zones including production lines, chemical handling areas, loading docks, and equipment operation zones. The system detected the presence or absence of helmets, safety vests, goggles, gloves, and safety boots in real time. Non compliance events triggered immediate audio visual alerts on the floor and notifications to shift supervisors. A compliance analytics dashboard tracked trends by zone, shift, and time period.
Measurable Impact
Technologies Used
The Challenge: Persistent Non Compliance
Manufacturing safety regulations require workers to wear appropriate personal protective equipment (PPE) at all times in designated zones. However, enforcing this policy across a facility with over 3,000 workers operating in three shifts proved extremely difficult with traditional methods. Safety officers could only be in one place at a time, and workers quickly learned to comply only when being observed.
The consequences of non compliance were serious. In the previous year, 23 safety incidents had occurred, including two that resulted in extended hospitalization. Beyond the human cost, each incident triggered regulatory investigations, insurance premium increases, and production downtime. The plant management team needed a solution that could monitor compliance continuously, not just during scheduled audits.
Previous attempts at improving compliance through additional training, posters, and penalty systems had shown only temporary improvements. The fundamental problem was the inability to monitor every worker in every zone at every moment, something only an AI powered system could achieve.
The Solution: Always On Safety Intelligence
Aptibit safety engineering team conducted a detailed risk assessment of all three facilities, mapping out PPE requirements by zone and identifying the highest risk areas for non compliance. Over 200 cameras were strategically positioned to provide comprehensive coverage of production floors, chemical storage areas, loading zones, and equipment operation stations.
The Visylix safety gear detection model was trained to identify multiple PPE categories with high accuracy: hard hats, safety vests, protective goggles, gloves, and steel toe boots. The system could distinguish between different PPE requirements by zone, so workers in chemical handling areas were checked for goggles and gloves while workers on the assembly line were checked for helmets and vests.
When a non compliance event was detected, the system triggered a three tier response: an immediate audio visual alert near the worker location, a mobile notification to the nearest shift supervisor, and a logged event in the compliance dashboard. This graduated response ensured that workers were reminded promptly without requiring direct supervisor intervention for every occurrence.
Cultural Transformation Through Technology
The impact of continuous monitoring extended beyond simple enforcement. Within the first month, PPE compliance rates jumped from approximately 82% to over 95%. By the end of the first quarter, compliance had stabilized at 99.7%. More significantly, the nature of non compliance events shifted from willful disregard to genuine oversights, such as a worker momentarily removing goggles while transitioning between zones.
Plant management noted a fundamental shift in safety culture. Workers reported that the AI system felt less punitive than supervisor led enforcement because it was consistent and impersonal. Everyone was held to the same standard regardless of seniority or relationship with management. Safety became a shared expectation rather than an external imposition.
Zero Incidents and Beyond
In the 12 months following full Visylix deployment, the plant recorded zero safety incidents attributable to PPE non compliance. This was a historic achievement for the facility, which had never previously achieved even a single quarter without an incident. Insurance premiums were reduced by 18%, and the plant received a commendation from the state industrial safety board.
The compliance analytics dashboard became a valuable management tool beyond safety enforcement. Shift level data revealed that compliance dipped during specific time periods, allowing management to adjust break schedules and conduct targeted refresher training. Zone level analytics identified areas where PPE requirements might need to be updated based on changing production processes.
Following this success, the manufacturing group has committed to deploying Visylix across all its facilities nationwide, with Aptibit serving as the long term implementation and support partner. The project has been presented as a benchmark case at multiple industry safety conferences in 2026.
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