Wienerberger: Enhancing Workplace Safety with Computer Vision

Wienerberger, a global leader in sustainable building materials and infrastructure solutions, prioritizes safety and operational excellence across its manufacturing sites. At its Kortemark facility, robotic arms operate within defined zones that employees can access, performing high-precision automated tasks. Although safety regulations were already in place, Wienerberger wanted to add an additional layer of security to prevent unauthorised entry into hazardous zones during robotic operation, thus eliminating potential accidents and costly production interruptions.

The key challenges included:

• Lack of real-time automated detection for unauthorised personnel.
• Maintaining production efficiency while enhancing workplace safety.
• Minimising false alarms and unnecessary stoppages.
• Complex integration requirements with existing automation systems.

To address these challenges, Wienerberger sought an AI-driven solution that would monitor restricted areas and automatically halt machinery if a person entered the predefined safety zone.

Faktion developed a real-time, AI-powered safety monitoring system uniquely tailored for Wienerberger, in close collaboration with Van Saet Security, ensuring compliance with all safety camera requirements and regulations. Unlike standard market solutions reliant on manual monitoring, Faktion's approach autonomously signals machinery via the existing PLC infrastructure, instantly stopping and restarting robotic arms without human intervention, minimizing downtime and significantly enhancing safety.

Solution highlights:

• Real-time, AI-based detection accurately identifies personnel entering hazardous areas, eliminating manual monitoring errors.
• Automated machinery controls halt and resume operations seamlessly, directly addressing productivity concerns.
• Integration into existing PLC-controlled automation systems, ensuring zero disruption to existing workflows.
• Minimised false alarms, drastically reducing unnecessary operational stoppages.

Faktion’s phased, strategic approach ensured maximum accuracy, reliability, and operational readiness:

1. Proof-of-Concept & optimisation: the initial phase involved deploying the AI system in a controlled environment, fine-tuning the detection mechanism, and addressing key challenges such as reducing false alarms. By iteratively improving the detection process, the system was optimised for accuracy and reliability.
2. Full-scale implementation & industrial integration: once validated, the solution was scaled to cover the entire operational area, with direct integration into Wienerberger’s PLC infrastructure. This setup ensured that robotic arms could be automatically halted and restarted, minimising downtime while maximising safety.
3. Operational deployment and future scalability: with the system fully implemented, the focus shifted to ensuring long-term stability. The AI-powered safety solution is now a core part of Wienerberger’s manufacturing operations, with potential for expansion to other sites across Europe.

Since implementation, the AI-powered safety system at Wienerberger’s Kortemark facility has dramatically enhanced operational safety without sacrificing efficiency:

• Proactive accident prevention through real-time AI-driven monitoring.
• Immediate machinery response, ensuring minimal operational disruption.
• Reduced false alarms, providing more reliable operational continuity.
• Scalable infrastructure, enabling potential future deployment at additional facilities.

The successful integration reinforces Wienerberger’s commitment to maintaining industry-leading safety standards and positions the company as a forward-thinking leader in leveraging innovative technology for workplace safety improvements.