Create Safer Work Environments with Sensors and Artificial Intelligence

BY: JEFF WILLIAMS

As Industry 4.0 and smart manufacturing approaches continue to change the manufacturing landscape, most discussions focus on automation, data analytics and process efficiency. However, one area that is frequently overlooked is how smart technology and artificial intelligence (AI) can improve workplace safety, especially for small and medium sized manufacturers (SMMs). Thanks to advancements in sensors, AI, and related connected systems, and the reduced cost of implementing these technologies, it is now possible to predict, detect, and even prevent common workplace hazards in ways that were impossible or unaffordable before. 

How Sensors are Changing the Game

Sensors provide the foundation for a safer, smarter workplace. These compact, often low-cost devices can now detect everything from proximity and vibration to temperature, gas levels, posture, and fatigue.

Proximity and motion sensors can prevent a worker from walking into an unsafe environment by slowing down equipment or even bringing it to a stop. The integration of force sensors is part of what adds the “collaborative” to “collaborative robots” (Cobots).  By utilizing sensors, the cobot can detect when an unexpected amount of force is applied and temporarily halt operations, which can make the difference between an operator being injured or not.  

Sensor equipment can also help monitor the health of our equipment, which can improve safety. Vibration, temperature, and acoustic sensors often can detect signs of wear or failure before a catastrophic breakdown occurs, such as an operator injury due to tool breakage.

Even if the sensors are not directly integrated into the equipment by the manufacturer, they are often added to increase efficiency. “Light Curtains,” which utilize an infrared beam, are often used to provide a virtual barrier between operators and equipment.  If anything—like a hand, arm, or tool—breaks the beam, the machine immediately slows or stops its motion to prevent injury.

Other sensors which may not be directly related to equipment in a facility can be leveraged to help increase overall workplace safety. According to the Occupational Safety and Health Administration (OSHA), over 500 U.S. workers die each year from exposure to harmful substances, such as airborne particles, gas leaks, or even temperature spikes—many of which can be mitigated by sensor technology. These sensors can detect hazardous conditions and provide an early warning that allows companies to correct issues or evacuate workers before injury occurs.

For some, the simple requirements of their role within an organization can affect their health over time. Wearable sensors, such as vests, can alert workers to poor posture or potential strain. Wristbands that track everything from heart rate to duration of standing/sitting to the wearer’s hydration level can help avoid potential problems. While more research is needed, recent studies by MDPI have identified a decrease in posture-related fatigue while using wearable sensors. (https://www.mdpi.com/1424-8220/25/5/1526).

Enhancing the Impact of Sensors with AI

One challenge sensors pose is they gather substantial amounts of data which must be filtered to determine appropriate actions. Advancements in modern AI and machine learning can significantly reduce the burden of processing data. Predictive analytics, for example, can help determine if equipment will fail, reducing the potential for safety issues due to tool crashes or other machine failure-related injuries. AI can also help predict anomalies before they occur with simulated tool paths, or by analyzing temperature fluctuations or work shift patterns which may cause fatigue.

Computer vision paired with AI can detect whether workers are wearing the appropriate protective gear (such as hard hats or gloves) or performing unsafe behaviors and can even monitor potential hazards such as congested aisles or blocked exits.

The Bottom Line

Industry 4.0 is not just about automating tasks–it’s about utilizing technology to help increase productivity and safety within our organizations. Sensors and artificial intelligence are emerging as effective and affordable tools to boost workplace safety in smaller manufacturing operations. These and many other innovations are helping Michigan manufacturers streamline operations, save money, and improve safety.

MMTC’s Technology Opportunity Assessments are a strong starting point for your digital transformation, and can assist manufacturers with understanding available technologies, determining suitable applications, exploring available funding, and planning implementation. MMTC also provides hands-on, personalized consulting with Solutions Experts focused on your biggest challenges. Contact us today to get started!

About the Author: Jeff Williams leads MMTC's efforts to educate and equip small and medium-sized manufacturers to guard against the growing threat of cyber-attacks. One of his main areas of focus relates to the cybersecurity requirements outlined in NIST Special Publication 800-171, designed to protect the information security systems of contractors working with the Department of Defense.