You cover the day. The plant runs sixteen more hours without you, and the night shift is where the shortcuts live.
Illustration · sample data · a miss, a place and a time · never a name
96% detection accuracy · 100+ sites live
What is PPE detection? It is your existing CCTV checking that every person on the floor is wearing what the job requires, every shift, and flagging a miss while the job is still running. No new hardware.
PPEAI · PPE AI · a PPE monitoring system on the cameras you already own
30-day pilot · two of your cameras · no long-term commitment
See what it reads
01 The problem
You are not short of rules, and you are not short of commitment. You are short of a record that forms without you writing it.
You cover the day. The plant runs sixteen more hours without you, and the night shift is where the shortcuts live.
A plant is a film. Four walkdowns a month across a site this size is a sample so small that the number it produces means almost nothing.
stops feeling like a shortcut. Nobody removed the guard to be unsafe. They removed it because the job was due and it was in the way.
Production has a bar chart. You have said the same thing four times and it keeps losing to a number, because they brought one and you did not.
02 What it is
Not a camera upgrade. Most PPE monitoring solutions start by asking what you will buy. AI powered PPE monitoring starts with what you already own, watches every shift instead of sampling four, and turns what it sees into a record you can take into a meeting.
Every person in frame, on every camera you nominate, for the whole shift. Not a walkdown. Not a sample. Every shift, including the two you are not there for.
A miss reaches the supervisor on the floor in seconds, with the camera, the zone and the time on it, while the job is still running and the fix still costs nothing.
Every miss lands in a record by zone, by shift and by week, that forms whether or not anyone remembers to write it. That record is what changes the committee meeting.
03 What it reads
Every check runs against the rule set for that zone, so a visitor walkway and a hot work bay are not held to the same standard. Every one ends in an alert to a person you name.
Hard hat and helmet, worn and correctly seated. The one check every plant starts with, and the one that quietly slips on the back shift.
Alert · a person in a hard hat zone without one
Vest or jacket in traffic zones, yards, docks and anywhere a vehicle shares ground with a person.
Alert · no hi-vis where vehicles move
Safety glasses, goggles and face shields at grinding, cutting, chemical handling and hot work.
Alert · face unprotected at a hot work permit
Gloves at the presses, the chemical bays and the packing lines, checked against what that zone requires rather than a blanket rule.
Alert · bare hands at a glove-mandatory station
Ear muffs and plugs in the compressor house, the blower room and anywhere the survey marked as a high-noise zone.
Alert · unprotected in a marked noise zone
Masks and respirators at the paint line, the dust zones and the solvent areas, where the exposure is invisible and the habit is the first thing to go.
Alert · respirator compliance below your line
Safety shoes at the stores, the loading bays and the shop floor, including the contractor who arrived in trainers.
Alert · footwear not to standard at entry
Harness worn and, where the camera sees the anchor, clipped. The check that matters most on the day it matters, because nobody is standing under the platform watching.
Alert · person at height, harness not detected
Full coverage checked at the change room exit before a person reaches the suite, in Grade C and Grade D areas.
Alert · coverage incomplete at the airlock
Pick any one of the nine · we prove it on two of your cameras in 30 days
04 How it runs
Our engineers walk the site and pick the existing cameras that see each zone well enough to read a person. Most plants already have the angles.
An edge unit inside your plant reads the video stream and checks each person against the rule set for that zone. The picture never leaves your network.
A miss reaches the people you name in seconds, with the camera, the zone and the time on it, while the job is still running.
Every miss lands in the console and the weekly readout, so Monday starts from numbers instead of memory.
05 What you get
The alert fixes today. The record is what you walk into the safety committee holding.
To the supervisor on that floor, by WhatsApp, the console or your existing alarm panel. Camera, zone, time, what was missing. Nothing to log in to.
Compliance by zone, by shift and by hour, on a screen in the EHS office and the control room. The night shift is visible in the morning without asking anyone.
Every miss, every zone, every shift, every week, built automatically. Six months of it is evidence. Six months of walkdown notes is a drawer.
Trend by area, repeat zones, shift comparison, contractor against own workforce. Written for the committee, not for an engineer.
06 Accuracy
96%
detection accuracy
PPE compliance monitoring is only worth having if the number it produces survives a challenge. Ours is 96% across 100+ live sites, from our own site reports. Accuracy is highest where the camera sees a person's upper body clearly at working distance, which covers most gates, walkways, bays, platforms and entries. That is where PPEAI is deployed and where the number comes from.
Our engineers survey before anything is quoted, and a camera that cannot do the job is reported as a camera that cannot do the job. You see the zone list and the confidence for each one before you commit to anything.
18,200+ unsafe acts recorded to date · across 100+ sites · on cameras the plants already owned
07 Deployment
All three are surveyed, installed and commissioned by our own engineers. Nobody is subcontracted.
Nothing leaves your network
The edge unit sits in your plant. Video is read on site and stays on site. Alerts and records stay inside your own network. The model for plants with a closed OT network or a strict data rule.
Video stays, events travel
Detection runs on the edge unit in your plant. The footage stays with you and only the event, the count and the alert leave, so dashboards and the monthly readout work from anywhere.
We run it, you read it
The same edge deployment, with our engineers holding monitoring, tuning and the zone rule sets. For sites without an IT team to carry it, or during a rollout across many plants.
The ones you already run. IP cameras with an RTSP stream, 2MP or better, positioned to see a person's upper body in the zone. The survey tells you which of yours qualify.
A wired link from the NVR or the cameras to the edge unit, and a power point in a cabinet. No rewiring of the plant.
A named supervisor per zone to receive alerts, and one EHS owner. Thirty minutes of their time at survey and an hour at handover.
Survey in week one. Pilot on two cameras live inside thirty days. A full plant usually follows in six to ten weeks depending on camera count.
They trust VB
10 Installed and running
100+
sites live
18,200+
unsafe acts recorded
96%
detection accuracy
0
new cameras needed
Source · VijAI deployment record across 100+ sites, to October 2026. Detection accuracy measured across live site deployments.
09 In their words
I have given that same toolbox talk four times.
Because a talk is an event and a habit is a hundred small moments, and nobody has ever been able to stand in all of them at once. One person, three shifts, and the arithmetic has never worked.
The camera is in all of them, on every shift.
Compliance is 98% when I am standing there.
Which is exactly what you would expect, and it tells you nothing about the two shifts you are not standing there for. A number measured only when observed is not a measurement.
The same check runs at 3 a.m. as at 11 a.m.
I know the night shift is different. I cannot prove it.
Nobody can, from four walkdowns a month. It is not that the evidence is being hidden. It is that no instrument on your site has ever been pointed at that question.
Compliance by shift, built without anyone writing it.
Production brought a chart. I brought my judgement.
And judgement loses to a chart in every meeting, every time, whoever is right. That is not a reflection on you. It is a reflection on who arrived holding numbers.
You arrive with the same kind of number they do.
08 Where it runs
09 Before you sign
Three questions that stall a signed-off deal for six weeks. Here are the answers, written so you can forward this page rather than rehearse them.
IT head
Nowhere, on the on-premise model. Detection happens on an edge unit inside your plant and the video never crosses your boundary. On hybrid the footage still stays on site and only events leave. You choose the model at survey, against your own network and data rules.
HR and the works committee
The system records a miss, a place and a time. Not a name and not a badge number. Identification is off unless you switch it on, and that is a decision for you and your works committee, never a default we ship.
Finance
Thirty days, one gate, two cameras you already own, and a readout at the end. No new hardware in the pilot and no long-term commitment to begin.
10 How it runs
The first question IT asks is where the video goes. All three answers are here, and detection by default with identification optional applies to every one of them.
| Model | Where the video is processed | Where it fits |
|---|---|---|
| On-premise edge | Entirely inside the plant. Nothing leaves your network. | Licensed areas, sites with a data-residency rule, and plants with no dependable outbound link. |
| HybridRecommended | Detection at the edge, dashboards and reporting hosted. Footage stays on site. Only events leave. | Most plants. Video stays inside the boundary and head office still gets one view across every site. |
| Cloud | Processing and storage hosted. | Single sites, short pilots, and estates already running their VMS this way. |
The model is chosen in the survey, against your network and your data rules. It is not a price tier.
11 Who installs it
Survey, engineering, installation, commissioning, calibration, training and support are all done by VB people. When a camera angle is wrong on a Sunday night, the person who fixes it is the person who chose it.
12 Questions
The cameras stay as they are. An edge unit reads their video stream and runs a vision model over it, so the same camera that recorded an incident last year can now flag the condition that leads to one, while the shift is still running.
PPE detection is your existing CCTV checking that every person on the floor is wearing what the job requires, and flagging a miss the moment it happens. PPEAI reads helmets, vests, gloves, harnesses, respirators and cleanroom attire at 96% detection accuracy.
A PPE monitoring system watches every shift rather than sampling. It alerts the supervisor on a miss while the job is still running, and it keeps a record by zone, by shift and by week that forms without anyone writing it.
An edge unit inside your plant reads the video stream from cameras you already own. A vision model checks each person in frame against the rule set for that zone. A miss raises an alert to the people you name, with the camera, the zone and the time on it, and the video stays on your network.
By hazard, by zone, not by a blanket rule for the whole plant. The survey walks each area with your EHS team and writes the rule set that applies there, so a visitor walkway and a hot work bay are never held to the same standard. PPEAI then enforces the rule each zone actually has.
In practice it means the right protection worn correctly, by everyone, for the whole task. The gap is almost never the policy. It is the hours nobody is watching, which is the gap a PPE detection system is for.
No. PPEAI runs on the CCTV you already have. The survey checks which existing cameras see each zone well enough, and the pilot starts on two of them.
96% detection accuracy across 100+ live sites. Accuracy is highest where the camera sees the upper body clearly at working distance, which is most gates, walkways, bays and entries.
Only if you switch it on. By default PPEAI records a miss, a place and a time, with no name and no badge number attached. Identification is a setting your HR and works committee decide, not a default.
On the on-premise edge model nothing leaves your network. On hybrid the footage stays on site and only events and counts leave. The model is chosen at survey against your network and your data rules.
Within thirty days. One gate, two existing cameras, real shifts, and a readout by zone, shift and hour at the end.
13 Also on this site
Two pages answer a narrower question than this one. Both are live today.
The clause, what an inspector reads first, and what a Grade C and Grade D entry has to show.
The requirement → L3 · Deliverable I need the documentWhat CAPA does an inspector accept after an airlock deviation?The fields, a worked example, and the five things that get one sent back.
The format →Nine modules, one camera network. PPEAI is usually the first one a plant switches on, because it is the one the floor can see working. The next one needs no new hardware either.
14 The next step
Nothing bought, nothing installed on the walls, and no commitment beyond the thirty days.
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