Industry
Manufacturing
Duration
3 months
Team Size
3 people
Client Overview
The client is a global manufacturer and exporter of cotton-based products used in the production of cosmetics, personal hygiene, medical, and cleaning applications. Their cotton products are supplied to textile mills and cotton-based manufacturers worldwide, operating within a high-volume industrial manufacturing environment that demands strict safety, compliance, and productivity standards.
Business Challenges
Managing workforce discipline, safety, and hygiene across expansive production floors became increasingly challenging for the client. Relying solely on manual supervision was ineffective for continuous monitoring, leading to several operational concerns:
- 1Unauthorized crowd formation in production areas, disrupting workflow and safety protocols
- 2Employee inactivity during working hours, reducing overall productivity
- 3Sleeping behavior during long or repetitive shifts
- 4Mobile phone usage in restricted zones, causing distractions and safety risks
- 5Food consumption within production areas, impacting hygiene and quality standards
- 6Non-compliance with mandatory safety gear, including head caps and masks
These challenges significantly affected operational efficiency, workforce discipline, and compliance with industrial safety standards.
Impact of the Challenges
- 1Decline in shop-floor productivity and operational efficiency
- 2Increased safety and hygiene risks in critical production zones
- 3Inconsistent enforcement of workplace policies
- 4High dependency on supervisors for continuous monitoring
- 5Lack of real-time visibility into employee behavior and safety violations
Solution Overview
- To overcome these challenges, the client partnered with Katomaran Technologies to implement an AI-powered Video Analytics solution. The solution seamlessly integrated with the existing CCTV infrastructure, enabling real-time detection of workforce behavior, safety violations, and hygiene non-compliance.
- Through intelligent monitoring, automated alerts, and centralized dashboards, the platform provided supervisors with actionable insights to ensure improved productivity, safety compliance, and operational control across the manufacturing facility.
Video Analytics Use Cases Implemented
Idle Employee Monitoring
Detects prolonged inactivity on the shop floor to ensure workforce productivity and task engagement.
Crowd Detection
Identifies unauthorized employee grouping in production areas to maintain operational discipline and safety compliance.
Mobile Phone Usage Monitoring
Monitors and alerts on mobile phone usage in restricted zones to prevent distractions and safety risks.
Food Consumption Monitoring
Detects eating or drinking inside production areas to maintain hygiene standards and quality compliance.
Head Cap & Mask Compliance Monitoring
Ensures workers consistently wear mandatory protective gear, including head caps and masks, in designated zones.
Sleep Detection
Identifies sleeping or resting behavior during working hours, enabling timely supervisory intervention.
Implementation Approach
- 1Assessment of existing camera coverage and production zones
- 2AI model tuning for factory-specific conditions such as lighting and movement patterns
- 3Configuration of alert rules for each use case
- 4Centralized monitoring dashboard for supervisors and safety teams
The deployment was carried out without disrupting existing operations.
Results & Outcomes
The implementation of Katomaran's Video Analytics solution enabled the client to achieve:
- 1Improved workforce discipline across production areas
- 2Enhanced safety compliance without manual enforcement
- 3Faster identification and resolution of behavioral violations
- 4Better visibility into shop-floor operations
- 5Reduced dependency on continuous human supervision
Why Katomaran Technologies
- 1Proven expertise in AI video analytics for industrial environments
- 2On-premise, secure, and scalable deployment
- 3Seamless integration with existing CCTV systems
- 4Customizable AI models tailored to manufacturing workflows
Conclusion
By leveraging Katomaran Technologies' Video Analytics, the client successfully transformed their manufacturing operations with intelligent, automated monitoring. The solution strengthened safety compliance, improved productivity, and delivered continuous operational visibility—supporting the client's global manufacturing standards and long-term growth objectives.
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