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.
Key outcomes
- 45%
- Caught-in risk reduced
- 60%
- Inspection time cut
- 150명
- Workers monitored simultaneously
- 8구역
- Equipment danger-zone geofences
Worksite overview
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.
Problems to solve
- Worker access control around automated equipment such as presses and robot arms was inconsistent
- Fatigue accumulation among repetitive and high-speed line workers could not be measured objectively
- Guard inspection and training history was scattered across paper records, slowing supervisor response
- Post-accident root-cause analysis depended on worker testimony
Solutions deployed by SenseZero
- 8 zones around presses and robots set as geofence danger zones — unauthorised access triggers immediate blocking alerts
- Cumulative heart-rate and activity monitoring via watch, with rest-recommendation alerts for fatigued workers
- Automatic recording of guard inspection and training completion history, bulk-downloadable during supervisor inspections
- When an accident occurs, worker location, heart rate, and work history at that moment are replayed in 5-second increments
Deployment timeline
PreparationWeek 1
Equipment layout analysis, identification of 8 danger zones, layout plan for 30 watches and 50 beacons
InstallationWeek 2~3
Beacon and watch installation, training for 150 workers, digital migration of guard history
Operations & validationMonth 1~3
Real-time monitoring + monthly alert trend analysis. KPI calculated at PoC conclusion
