Worker Protection And Safety Protocols At Unilever Factories

Enhancing Worker Protection and Safety Protocols at Unilever Factories

Unilever, a global leader in consumer goods, is committed to ensuring the highest safety standards across its factories.

Improved Defect Accuracy

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Automation of Quality Control

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About Unilever

Unilever, a global leader in consumer goods, is committed to ensuring the highest safety standards across its factories. To strengthen worker protection and enhance compliance with safety protocols, Unilever aimed to implement a smart monitoring system across its RYK, Foods, and ICF facilities. The focus was on ensuring workers followed PPE guidelines, detecting potential safety risks, and maintaining clear emergency exits while monitoring machine guard operations.

To achieve these goals, Unilever collaborated with The Disrupt Labs to deploy an AI-powered safety monitoring system. This advanced solution provided real-time tracking, automated alerts, and proactive risk management, helping Unilever create a safer work environment while improving operational efficiency.

The Challenge

Ensuring worker safety in a fast-paced factory environment came with several challenges:

01.

Worker Protection

Ensuring that employees consistently wore PPE, including helmets and vests, in high-risk areas.

02.

PPE Compliance Monitoring

Detecting whether workers were properly wearing safety gear using real-time monitoring.

03.

Forklift-Person Safety

Identifying close interactions between forklifts and workers to prevent accidents.

04.

Machine Guard Monitoring

Ensuring machine guards remained closed during operation to minimize injury risks.

05.

Emergency Exit Monitoring

Keeping emergency exits clear at all times to ensure a safe evacuation route in case of an emergency.

06.

Adapting to Dynamic Environments

Maintaining system accuracy despite changing lighting conditions and constant worker movement.

“The AI-based PPE Monitoring System from The Disrupt Labs has transformed our approach to workplace safety. Automating PPE monitoring has minimized human error, brought compliance levels to over 95%, and saved us countless hours previously spent on manual tracking. The system’s intuitive dashboard and automated reporting allow our management team to make informed, data-driven decisions, significantly boosting both safety and operational efficiency. It has truly set a new benchmark for safety at our facility.”

M/S Axens

Representative

The Solution

The Disrupt Labs implemented an advanced AI-driven safety monitoring system, specifically designed to address Unilever’s safety challenges.

Helmet and Vest Detection

The system accurately identified whether workers were wearing the required PPE, using AI-based pose estimation and real-time tracking to prevent false detections.

Forklift-Person Proximity Alerts

The system detected close interactions between forklifts and workers, triggering real-time alerts to prevent accidents.

Machine Guard Monitoring

ArUco markers and ROI (Region of Interest) analysis were used to confirm that machine guards remained closed during operation, ensuring compliance with safety standards.

Emergency Exit Monitoring

AI-powered object detection ensured that emergency exits remained unobstructed by continuously tracking objects in designated zones.

Seamless Integration

The system was designed to work with existing factory operations without disrupting workflows, ensuring smooth implementation.

The Outcome

The Football Defect Inspection System delivered exceptional results for Forward Sports:

87% Accuracy in Real-Time Monitoring

The system ensured highly precise detection of safety violations and compliance issues.

98% PPE Compliance Achieved

The monitoring system helped workers adhere to safety protocols, reducing violations.

Fewer Workplace Accidents

Real-time alerts for forklifts, machine guards, and emergency exits helped prevent accidents before they happened.

Operational Efficiency

Automated tracking and reporting reduced manual safety checks, allowing teams to focus on critical tasks

Scalability for Future Growth

The system’s modular design allows easy expansion to cover additional safety features or new factory locations.

Conclusion

The AI-powered safety monitoring system implemented at Unilever factories has transformed workplace safety by ensuring PPE compliance, preventing hazards, and improving emergency preparedness. By using real-time monitoring and automated alerts, the system has reduced safety risks and streamlined operations. This project highlights how technology-driven solutions can help industries enhance worker protection and meet global safety standards. Unilever’s commitment to innovation and safety sets an example for industries worldwide, demonstrating how smart monitoring can create a safer and more efficient workplace.

Enhancing Worker Protection and Safety Protocols at Unilever Factories

About Unilever

The Challenge