Safety compliance detection on a live factory floor
Industrial real-time PPE detection framework
A real-time AI safety monitoring system for manufacturing environments. It reads existing industrial CCTV, detects helmet and safety-vest compliance frame by frame, and raises an instant alert the moment someone walks onto the floor without them — no new hardware, no guard watching a wall of monitors.
Compliance was a clipboard exercise.
PPE rules on a manufacturing floor are only as good as the person checking them. Spot audits catch a fraction of violations, cameras already recording everything are watched by nobody, and by the time a near-miss is reviewed the footage is a week old. The client needed the cameras they already owned to do the checking — continuously, and loud enough to act on.
Three moving parts, one existing camera network.
Live CCTV streaming straight off the industrial camera infrastructure already installed on site.
A custom computer-vision model integrated with Frigate NVR, inferring on every frame as it arrives.
Instant notification the moment a violation is seen, with the state visible on screen for the floor supervisor.
What the model sees.
Real-time identification with bounding-box visualisation, tuned for hard hats under mixed factory lighting.
Automated validation of both hard hat and high-visibility vest, resolved per person on a wide-angle floor feed.
Simultaneous helmet and vest identification per person in frame.
Continuous monitoring with minimal latency between event and alert.
Clear on-screen indicators so a supervisor can see what the model saw.
Instant violation notifications, tracked over time rather than one-off.
Honest notes
The hard part was never the model — it was the frame budget. Running inference on every camera at once meant choosing what to skip, and being honest about the false-positive rate rather than tuning it away in a demo. A supervisor stops trusting an alert system the second it cries wolf twice.
I build vision systems that survive the shop floor.
If you have cameras already recording and nobody watching them, that's usually a two-week conversation. Send a short brief and I'll come back with scope, timeline and price.