The Internet of Things (IoT) is transforming manufacturing, from boosting productivity and efficiency to safeguarding worker health and safety. At Digital Catapult, we have seen firsthand how leveraging IoT solutions including interconnected sensors, devices, and data analytics, can provide real-time monitoring, early warning systems, and proactive safety measures to manufacturers.
Interconnected devices and real-time monitoring will enable businesses to create smarter, safer work environments while improving overall operational efficiency, fostering a culture of proactive safety.
Enhancing environmental monitoring and hazard detection
A key application of IoT in manufacturing safety is environmental monitoring. Sensors can continuously measure air quality, temperature, humidity, and the presence of hazardous gases or particles. Industrial emissions account for an estimated tenth of the UK’s total, and air pollution is one of the greatest environmental risks to public health, linked to an estimated 29,000 to 43,000 deaths each year. By collecting real-time data, IoT technologies allow for immediate detection of unsafe conditions, triggering automated responses such as ventilation system adjustments or emergency shutdowns, to minimise emissions and to prevent any further environmental damage.
Advanced cameras equipped with Artificial Intelligence (AI)-powered computer vision algorithms can also continuously monitor the work environment, identifying potential hazards in real-time. These systems can detect unsafe conditions such as spills, obstacles in walkways, or improperly stored materials. Importantly, they are exceptional at ensuring proper use of Personal Protective Equipment (PPE). The AI can instantly recognise if a worker enters a zone without the required safety gear. When integrated with IoT, these systems can trigger immediate alerts, automatically locking out dangerous equipment until safety compliance is achieved.
Over time, the data collected can identify patterns in safety violations, allowing for targeted training and improvements in safety protocols. This combination of IoT and computer vision not only enhances immediate safety but also contributes to fostering a proactive safety culture at work, clearly demonstrating IoT’s role in mitigating environmental damage and improving safety in manufacturing settings.
Introducing IoT wearables in industrial environments
Wearable IoT devices can monitor workers' vital signs and exposure to harmful elements, alerting them to potential health risks before they escalate into serious issues. Wearable IoT devices in industrial settings have evolved to become sophisticated health monitoring tools and these devices, which can take the form of wristbands, badges, or even smart clothing, are equipped with an array of sensors that continuously monitor various physiological and environmental parameters.
Wearables offer powerful solutions for proximity detection to enhance worker safety. Their integration in high-precision tracking systems allows for centimetre-level accuracy in determining the positions of workers’ equipment and potential hazards, creating dynamic safe zones around machinery or hazardous areas. If a worker enters a danger zone, the system can trigger immediate alerts, automatically slow down or stop equipment, or activate protective barriers. This is particularly important as the manufacturing industry is third behind construction and agriculture, forestry and fishing for fatal workplace accidents.
As part of our IoT Foresight and Experimentation project, Digital Catapult assessed three critical parameters for proximity detection solutions: reliability in detecting proximity violations, power consumption, and configurability. Our evaluation focused on solutions from five international companies, where we offered insights to refine and enhance their products, with a view to deploying these solutions in real-world environments.
Moreover, these devices can be integrated with other safety systems. For instance, if a worker's vitals indicate fatigue, the system could temporarily restrict their access to high-risk areas or machinery. In emergency situations, the wearables’ location tracking feature can guide rescue teams directly to a worker, further demonstrating how IoT technologies can mitigate safety risk for workers while maintaining levels of operational efficiency.
Making machinery and other equipment safer
IoT can also enhance equipment safety and maintenance. Smart sensors attached to machinery can detect unusual vibrations, temperature changes, or other indicators of potential malfunction. This predictive maintenance approach not only prevents unexpected breakdowns but also reduces the risk of accidents caused by equipment failure.
Industrial robots may exhibit erratic movements, electrical systems could spark fires or discharge unexpectedly, and mechanical failures can propel components at high velocities. Even safety mechanisms like light curtains or motion detectors are susceptible to failure, potentially compromising the overall safety of facility machinery for operators and nearby workers.
IoT-enabled remote monitoring systems offer a proactive solution to these challenges. Deploying a network of IoT sensors can provide continuous tracking of operational parameters such as temperature fluctuations, vibration levels, timing discrepancies, Revolutions Per Minute variations, and lubrication status, all in real-time. This data enables predictive maintenance strategies, allowing teams to detect anomalies, forecast potential failures, and address issues before they escalate into safety hazards or cause operational disruptions.
The long-term benefits of IoT technologies extend beyond immediate safety improvements. The wealth of data can inform better workplace policies, optimise shift schedules, and contribute to the design of safer work environments. However, it's important to implement these systems with careful consideration of privacy concerns and clear communication about how workers’ data is used to ensure acceptance and compliance.
At Digital Catapult, we support businesses that want to integrate IoT into their operations as we know that the future of manufacturing safety is smart, connected, and deeply human-centred. Any organisation interested in learning and witnessing how IoT is revolutionising worker health and safety can visit Digital Catapult’s Industrial IoT Experience Lab or click here: www.digicatapult.org.uk/apply/labs/future-networks-lab
Ramona Marfievici, principal IoT Engineer at Digital Catapult
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