CASE · Manufacturing

Large Manufacturer B
Smart factory worksite

Beacon-based location tracking and danger-zone alert systems were applied to manufacturing lines with high caught-in and collision accident risk.

OVERVIEW

Worksite overview

Industry

Manufacturing

Scale · Duration

150 workers · 3 months

Deployment configuration

30 watches · 50 beacons · 8 geofence zones

Manufacturer B wanted to reduce caught-in and collision accident risk in a smart factory running many automated machines, while also objectively measuring worker fatigue accumulation. A 3-month PoC using SenseZero's smart watches, fixed beacons, and geofences achieved a 45% reduction in caught-in hazard alerts and a 60% reduction in safety inspection time.

KPI

Key outcomes

45%

Caught-in risk reduced

60%

Inspection time cut

150명

Workers monitored simultaneously

8구역

Equipment danger-zone geofences

CHALLENGES

Problems to solve

01Worker access control around automated equipment such as presses and robot arms was inconsistent
02Fatigue accumulation among repetitive and high-speed line workers could not be measured objectively
03Guard inspection and training history was scattered across paper records, slowing supervisor response
04Post-accident root-cause analysis depended on worker testimony

SOLUTION

Solutions deployed by SenseZero

S.018 zones around presses and robots set as geofence danger zones — unauthorised access triggers immediate blocking alerts
S.02Cumulative heart-rate and activity monitoring via watch, with rest-recommendation alerts for fatigued workers
S.03Automatic recording of guard inspection and training completion history, bulk-downloadable during supervisor inspections
S.04When an accident occurs, worker location, heart rate, and work history at that moment are replayed in 5-second increments

TIMELINE