Complying with safety regulations is a challenge for most companies, but even more so for large manufacturers. The consequences of non-compliance are huge too. According to a Ponemon-Global Scape report, the annual cost of non-compliance with regulations has increased by 45%. This can range anywhere from $2.2 million to $39.2 million.

As challenges like worker safety gain more prominence, the manufacturing industry faces concerns dealing with regulations about workplace safety and the associated financial costs.

In terms of manufacturing output, Deloitte reports that production output in the U.S remains lower than the 2019 levels. In fact, since the year 1998, regulatory costs in manufacturing have increased 7.6% each year, while output has only increased by 0.4%.

This begs the question – what are the biggest challenges that large manufacturers face when complying with safety regulations? And what is the best solution to these challenges? Let’s discuss.

1. Employee Safety 

According to the U.S. Bureau of Labor Statistics, there were 4,764 fatal work injuries recorded in 2020. The rate of fatal injuries among workers was 3.4 for every 100,000 full-time workers.

Besides the immense human cost & loss of productivity, “poor” safety norms can directly cost the manufacturers in terms of treatment expenses and penalties. Manufacturers also need to deal with health-related challenges like workplace stress, mental health problems, and occupational health hazards like improper breathing and musculoskeletal disorders. 

2. COVID-19 Impact 

According to a survey conducted by the U.S. National Association of Manufacturers, 53% of manufacturing companies anticipated a change in operations (following the pandemic outbreak). Besides, 35.5% of U.S-based manufacturers faced supply chain disruptions.

In the wake of the global COVID-19 pandemic, global manufacturers have faced multiple operational challenges. While some manufacturers were temporarily shut down, others faced a slew of changing safety norms and regulations.

COVID-induced safety guidelines included physical distancing (among workers), regular sanitization of the facilities, and regular worker health checkups. Some of the other effective measures included measuring the worker’s body temperature and checking if proper mask mandates are being followed. The shifting norms and the operational challenges of enforcing these norms have remained a major concern even as the pandemic winds down.

3. Machine Maintenance

In the manufacturing domain, machine maintenance is also critical to the safety of its operators and workers. Equipment failure can account for over 40% of unplanned downtime and expose the facility staff to higher safety risks. 

In this regard, preventive maintenance (instead of reactive maintenance) is preferred by 80% of maintenance personnel. Over 60% of industrial companies associate preventive maintenance with reduced machine downtime and improved safety.

In today’s industrial age, manufacturers leverage connected devices and machines for predictive maintenance. For instance, digital tools are monitoring “aging” machines in hazardous environments for any corrosion, wear & tear, and defects. With real-time machine data, predictive maintenance tools can detect any early signs of machine deterioration and raise immediate alerts. 

4. Defective Products

Defective and damaged products cause financial losses to manufacturers and adversely impact their reputations. Product damage can occur at any stage, including production, packaging, and shipping. For instance, improper packaging of food items can lead to health issues due to contamination.

In an OECD analysis, 55% of 60 selected products were found to be defective and non-compliant with product safety standards. Product manufacturers are often liable for damages for delivering “defective” products or for inadequately warning consumers about the correct use of “dangerous” products.

As such, manufacturers can no longer rely on “manual” (or human) monitoring of defective products. Technology can automate this process and ensure that products reach their consumers safely. 

5. Physical Security

Physical security and thefts are major concerns within any manufacturing plant. Over 75% of employees have admitted to stealing from their employers. Small thefts account for 5% of annual revenues, while inventory losses are as high as 43% in the U.S.

Physical security issues include the entry of unauthorized personnel to selected facility premises. That said, emergency exits should be “free” from all obstructions to facilitate easier worker movement during any crisis.

Next, let us see how KamerAI leverages its Computer Vision solution to address these manufacturing industry challenges.

How KamerAI Solutions Help in Overcoming Manufacturing-related Challenges

At KamerAI, we leverage the power of visual data captured through CCTVs and high-resolution cameras in public spaces. Powered by Artificial Intelligence (AI) and Computer Vision (CV), KamerAI delivers an automation platform for manufacturing enterprises that makes it easy to integrate sophisticated computer vision technology into such sensitive areas.

Using KamerAI technology along with cameras, manufacturers can now provide a safe working environment for their employees and monitor their delivered products. Here are some of the capabilities of the KamerAI CV solutions that are useful in the manufacturing industry:

Product Inspection

KamerAI allows consistent product surveillance along the manufacturing line within any facility. This ensures that the final products are without defects and meet the expected standards when they reach the customer.

Predictive Maintenance

KamerAI solutions enable effective predictive maintenance by monitoring every piece of equipment in the facility. With real-time machine data, maintenance operators can proactively address machine-related problems. This helps them resolve the minor issues before they lead to machine downtime.

COVID-19 Safety

With KamerAI, manufacturers can track and enforce COVID-19 safety guidelines in their facilities. With features like facial mask detection, PPE compliance, and thermal imaging, KamerAI provides a non-intrusive mode of spotting workers without face masks or having high body temperatures.

Worker Safety

KamerAI solutions enable manufacturing companies to ensure workplace safety. Using real-time monitoring, it can detect and report employees violating safety standards — for example, workers not wearing the necessary protective equipment or being distracted when operating a machine.

Worker Trespassing

KamerAI solutions can automate employee timekeeping using facial recognition technology. This means it can leverage perimeter security to detect trespassing and maintain access control.

Conclusion

Manufacturing companies can no longer rely on manual processes to maintain compliance with safety regulations. Enter KamerAI.

KamerAI is an end-to-end automation platform that our customers use to derive business benefits from CV technology. With our solutions, your manufacturing business can always remain compliant with safety regulations and avoid any high costs & penalties. Get in touch with a KamerAI consultant today!