Manufacturing · Safety compliance monitoring
A near-miss written up at shift end has already failed
Banao builds AI safety monitoring for production lines — PPE detection, restricted-zone entry, ergonomic overload, and environmental threshold alerts — capturing incidents as they happen, not in the next daily report.
The system runs on your existing CCTV and IIoT sensors, feeding a compliance dashboard that gives safety officers and plant heads verified evidence before an audit or injury demands it.
CP Plus— computer-vision compliance layer deployed over existing CCTV on a manufacturing floor.
The first call is free · 45 minutes · no obligation
What we build
What a Banao safety monitoring deployment covers
Compliance monitoring is not a single sensor. It is detection, evidence, alert routing, and audit trail — we build all four.
PPE detection on every worker, every shift
Helmet, vest, gloves, and face-shield compliance checked on every worker entering hazard zones, per shift, without a manual audit walk.
Restricted-zone and proximity alerts
AI flags any person entering a restricted area or approaching moving equipment — with real-time alerts to floor supervisors before contact, not after.
Ergonomic overload and posture monitoring
Pose estimation models identify high-risk manual handling patterns and repeated-strain postures — the kind of exposure that produces an injury claim six months later.
Environmental and threshold event logging
IIoT sensor feeds — gas, temperature, pressure, noise — monitored against your compliance thresholds and logged with timestamps for regulatory submission.
Audit-ready compliance dashboard
Safety officers get a shift-by-shift compliance rate, incident log, and trend view — structured so the data maps directly into ISO 45001 and local statutory reports.
Incident replay and root-cause evidence
When an incident or near-miss occurs, the system surfaces the relevant camera feeds, sensor readings, and alert history as a timestamped sequence — not a blank gap in the record.
Receipts
Where this is already running
Metrics shown dotted (··) are being finalised in our case-study metrics pack — published only once verified.
Vision compliance layer added to existing CCTV infrastructure
Floor safety checks were manual, inconsistent, and shift-dependent. Banao added a computer-vision compliance layer over the existing CCTV network — no camera replacement — to detect PPE violations and proximity breaches in real time and route alerts to supervisors.
Dogfooding
We run AI on our own operation before yours
Banao operates a ~300-person engineering company on its own AI products. InterviewGod screens our own engineering hires; Vikaas runs our own demand-generation pipeline. A system has to survive daily use inside Banao before we deploy it on a client's floor.
That discipline applies to safety monitoring: the models we build carry real accountability — regulatory, reputational, and operational. We do not ship a system we have not stress-tested on our own processes first.
Screens Banao's own engineering hires every week.
Runs Banao's own demand-gen pipeline end to end.
The honest version
When AI safety monitoring is the wrong starting point
A camera system does not fix every compliance problem. We will tell you before you spend:
- Process culture gaps: if safety violations go unreported because of management pressure, not detection failure, alerting technology will not close the gap.
- Poor existing infrastructure: sites with no workable camera coverage or sensor data need an infrastructure audit first — the AI layer comes after.
- Low-frequency, very-high-consequence events: for rare ATEX or HAZMAT scenarios, engineering controls and physical interlocks take priority over AI detection.
How we start
How we start — assess before we build
We do not quote a compliance system off a site plan. We review your actual floor layout, camera coverage, and incident history first.
- 01
AI Discovery Sprint
2 weeks · fixed price
We audit your current CCTV coverage, sensor feeds, and compliance records, test detection feasibility on your specific hazard zones, and hand back a coverage map and build estimate — yours to keep. If you proceed, the Sprint cost is credited against the build.
- 02
Build
Model training on your site's PPE specs and hazard zones, integration with your camera network and IIoT sensors, alert routing to your safety team's existing tools.
- 03
Production & continuous audit
Live monitoring with a compliance dashboard, regular threshold review against your regulatory obligations, and incident replay capability for any statutory investigation.
FAQ
Frequently asked questions
Does it work on our existing CCTV cameras?
In most cases, yes. Banao deploys computer-vision models over existing camera infrastructure where resolution and placement are workable. The Discovery Sprint establishes which zones are covered, which need repositioning, and where a new camera is the only option.
How accurate is PPE detection in a busy visual environment?
Accuracy depends on camera placement, lighting, and the PPE types involved. The Discovery Sprint tests detection on your actual site footage against your specific PPE set — helmets, vests, gloves — before any build commitment. We do not quote accuracy off a generic benchmark.
Can it generate reports for ISO 45001 or statutory submissions?
Yes. The compliance dashboard is structured to produce shift-by-shift records, incident logs, and trend data in formats that map to ISO 45001 and common statutory requirements. The exact report schema is scoped during the build to match your local regulatory obligations.
How do we handle worker privacy and data retention?
Banao builds safety monitoring within your data residency requirements. Images and sensor records are retained only as long as your policy requires, and PII handling is scoped to what your local labour law and any site agreements allow. This is addressed explicitly in the Discovery Sprint.
What happens when an alert fires — who gets notified and how fast?
Alert routing is configured to your org structure — floor supervisor, shift safety officer, plant manager — via your existing tools (Teams, SMS, a control-room display). Real-time alerts for proximity and zone breaches; shift-end summaries for PPE compliance rates.
Get started
Show us your compliance gap — we'll show you where AI closes it
In 45 minutes we can review your current safety monitoring approach and tell you whether AI detection is the right next step — and what the build would take.
Book a Discovery Sprint