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Autonomous Worker Safety & PPE Compliance Monitoring in Heavy Plants

A primary steel manufacturing mill operating high-risk melt shops, rolling mills, and heavy material handling yards equipped with 250 existing CCTV security cameras.

Runs onArjuna
PPE compliance rates increased
68%PPE compliance rates increased
reduction in lost-time workplace injury incidents
72%reduction in lost-time workplace injury incidents

How the work runs

The pressure that made this worth automating, the steps the system runs, and what came out the other side.

Pressure & Trigger Points

  • Worker safety non-compliance (missing hard hats, high-visibility vests, safety goggles, or thermal suits) caused high workplace injury rates.
  • Safety officers could not monitor 250 video feeds manually in real time, catching safety violations only after accidents occurred.
  • Installing specialized AI safety cameras across the 50-acre plant was cost-prohibitive.

The run · 5 operational steps

Click any step to inspect telemetry signals, model reasoning, and governance gates.

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1

Retrofit RTSP CCTV Stream Ingestion

Arjuna connects to all 250 existing CCTV camera RTSP video streams without requiring hardware replacements.

Input Signal:

Real-time operational telemetry & queue

Reasoning Pattern:

MCP grounded vector inference

Governance Gate:

Policy constrained with audit write-back

Verified Business Outcomes

  • PPE compliance rates increased from 68% to 99.4% within 30 days of deployment.
  • 72% reduction in lost-time workplace injury incidents.
  • Zero capital expenditure spent on new cameras by retrofitting 100% of existing CCTV infrastructure.

Capabilities this relies on

  • vision perception
  • anomaly detection
  • alert routing
  • policy compliance
  • in boundary deployment

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