Case Study

Empowering Steel Plant Excellence with VijAI

The system was integrated with the plant's existing CCTV infrastructure and industrial network

PPEAI

Detects whether workers are wearing helmets, vests, gloves and flags safety violations.

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FIREAI

Monitors CCTV feeds to detect fire or smoke in high-risk areas for instant emergency response.

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GESTEAI

Prevents distractions on busy manufacturing floors by detecting unsafe gestures like mobile phone use, inattentive movement, or careless walking near CNC machines, robotic arms, overhead cranes, or heavy components in motion.

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DRIVEAI

Monitors vehicle motion, reversing, speeding or rash driving in factory/logistics zones.

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ZONEAI

Monitors restricted, hazardous and safe zones via CCTV, triggering alerts for unsafe presence.

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PULSEAI

Counts people, vehicles or objects in factory zones, enabling realtime occupancy analytics.

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SAFEAI

Detects unsafe behaviours such as barrier jumping, improper lifting, missing handrails.

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SECUREAI

Uses facial recognition and motion detection to prevent unauthorized access to control rooms, tool rooms, high-value material storage, automated production cells, and hazardous machinery zones—significantly reducing safety and security breaches.

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GUARDAI

Continuously checks heavy manufacturing equipment—like presses, CNC machines, furnaces, conveyors, cranes, and robotic arms—to ensure protective guards, lockouts, and safety barriers are restored after maintenance, preventing unsafe restarts and mechanical hazards.

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The system was integrated with the plant's existing CCTV infrastructure and industrial network.

VijAI Impact Statistics

dropped by 42%

unsafe-act incidents

declined significantly

unsafe vehicle behaviours

improved by 20%

truck turn-around time

continuous improvement.

compliance scores

The client's key pain-points included:

In large industrial plants and warehouses, safety teams often rely on manual monitoring and reactive responses. Common issues include:

Frequent PPE compliance violations (helmets, vests, gloves) in hot-zones.

Unsafe vehicle movements in the logistics yard (forklifts, trucks reversing).

Unauthorized access to hazardous zones (ladle pouring, high-voltage substations).

Near-miss incidents and high cost of manual supervision.

Why VijAI Was the Right Fit?
* Tailored for industrial settings: VijAI is designed for heavy manufacturing, foundries, steel plants, logistics yards and high-risk zones — not just generic office camera monitoring.
* Modular & scalable: The plant could roll out the modules zone-by-zone (starting with high-risk casting and logistics) and scale later across their entire facility.
* On-premise + cloud flexibility: Critical for steel plants where network latency, connectivity and security matter.
* Proven accuracy and deployments: The solution reports over 10 million+ data-points processed, training hours exceeding 30,000, and many deployed sites globally.
* Alignment with sustainability & safety strategy: The plant could tie usage of VijAI to its digital-transformation, smart-factory and ESG goals.

Implementation Tips for Steel Plants
* Start with high-risk zones: Prioritise modules like PPE AI and ZONE AI around ladle lines, cranes, hot-rolling mill entry points.
* Audit CCTV coverage: Ensure cameras provide sufficient resolution, coverage and lighting for AI detection.
* Define clear rules: Setup zone definitions, behaviour triggers (e.g., no vehicle above X speed in yard), and configure alerts accordingly.
* Integrate alerting: Link with your EHS management system and supervisors mobile notifications for fast action.
* Use data-dashboards: Review weekly and monthly dashboards from PULSE AI and SAFE AI to identify patterns and drive continuous improvements.
* Scale gradually: Roll out one module/zone at a time, measure results, then expand across the plant network

Conclusion
For steel-manufacturing plants seeking to become safer, smarter and more efficient, the VijAI suite from VB Group offers a powerful, industrial-optimized AI-vision platform. By deploying modules such as PPE AI, DRIVE AI, ZONE AI and SAFE AI, the featured plant achieved significant incident reduction, improved asset uptime, better compliance and operational efficiency.