PPE compliance
Hard hats, hi-vis, safety glasses, gloves, hearing protection — flagged at the moment of entry, not on next week's audit.
AI for the factory floor
Run your floor on signal. Safety and operations, one camera tree.
Most plants pay one vendor to keep the floor safe and another to keep it running. FactoryOps AI puts both on the cameras you already have — extended by a phone companion app for the blind spots, and rolled out with a capability ladder that only asks operators to do what the data says they're ready for.
Alert · 12s ago
Forklift entered pedestrian lane · Dock 3
Illustrative AI overlay on a stock plant photo (Pexels — Yetkin Agac).
- Camera source
- Existing CCTV (RTSP / ONVIF)
- Extra coverage
- iOS & Android companion app
- Rollout
- Earned, not launched
Layer one — Safety
Catch every safety risk the moment it happens.
The risks responsible for the majority of recordable incidents on industrial sites — picked up in real time, on cameras and phones you already own.
Restricted zones & vehicle proximity
Forklift–pedestrian conflicts, exclusion-zone breaches, loading-dock interactions. Trigger alarms before contact.
Falls, slips, ergonomics
Working-at-height violations, slip/trip risks, lifting posture, unsafe ladders and reach. Coaching, not surveillance.
Fire, smoke, spills
Early detection of smoke, flame, and liquid spills — including in areas not covered by sensors.
Layer two — Operations
The same cameras keep the floor running.
An append-only event spine — vision events, operator entries, maintenance logs, truck movements — that gives you live OEE, changeover times, dispatched kg, and a 06:45 daily report you can actually trust.
Truck visit · IN · Dock 3
Open 8 min 22 s · 120 sacks logged
Stock plant photo (Pexels — Elevate).
Run state & OEE
Light state, motion zones, and cycle detection turn into live run/idle/distress and rebuildable OEE intervals — without instrumenting the line.
Changeovers & quality
Product changeovers tracked end-to-end, with backed-by-evidence quality checks (weights, dimensions, first-good-part) in band or flagged.
Truck visits & material flow
Vehicle in / out becomes a truck visit. Operators log what moved in append-only line items with photo evidence — inbound scrap, outbound crates, weighbridge slips.
Maintenance & uptime
Recurring tasks generated from templates — per-shift, daily, per-N-cycles, per-run-hour. A missed check is data, not silence.
Companion app
The camera platform that goes where CCTV can't.
Other AI platforms stop at the camera tree. FactoryOps AI extends to every phone on site — for alerts, capture, and coverage of the blind spots that actually cause incidents and downtime.
Codename: Forge Ops — phone-OTP sign-in, roster-only access, EN/KN/HI from day one.
Frontline alerts
Push the right alert to the right supervisor in seconds. Acknowledge, escalate, or close the loop from the floor.
Phone-as-sensor
Cover blind spots CCTV can't see — outdoor yards, contractor zones, mobile equipment, temporary work sites.
Site walk & onboarding
Walk the plant once with your phone to map cameras, define restricted zones, and tune detections. No integrator required.
Incident & near-miss capture
EHS teams and operators capture incidents and near-misses with the phone camera — same model, same case file, same trends.
Capability ladder
Rolled out the way good training programs work.
Plants don't fail because the AI doesn't work — they fail because they're asked to do too much at once. Every capability in FactoryOps AI moves through measured stages. A duty arrives when the data says the floor is ready, and is retired the same way: with data.
- Hidden
- Pilot
- Live
- Retiring
- Retired
- Stage 1Hidden
Capability is built but invisible. Nothing on the floor, nothing in the inbox.
- Stage 2Pilot
Visible to one trusted operator. Their data proves the UX works before the floor sees it.
- Stage 3Live
Released with a single 'what's new' card per user — one screen, not a tour.
- Stage 4Retiring → Retired
When the AI's agreement rate with operators stays above 95% for 28 days, the manual check is recognised as no longer needed and shed.
The ladder is the same whether the capability is a safety check or a production duty. Audits and customers can still demand a capability before the gate is met — overrides are recorded as data, not hidden as a workaround.
Under the hood
Hybrid by design. The plant runs even when the uplink doesn't.
Vision stays on the floor. The cloud owns truth, evolves the schema, and routes alerts. Critical alarms are mirrored at the edge so a dead uplink never silences a starvation event.
Plant — Edge
- Existing CCTV (RTSP / ONVIF)
- Companion-app phones
- Edge box · outbox + local rules
Video stays at the plant
events
signed batches
Cloud
- Ingest + enrichment
- Safety detections
- Ops derivations (OEE, changeovers, logistics)
- Alarm engine + capability evaluator
Postgres · append-only events
alerts + tasks
Web Push + REST
Floor — Phones
- Frontline alerts & acknowledgement
- TASKS tab (filtered by ladder state)
- 06:45 daily report
Operator · Supervisor · Owner
Events flow up · config flows down (60 s poll).
Outage-safe: edge outbox holds ~7 days of events.
Critical alarms mirrored at the edge — never silenced by a dead uplink.
How it works
- 01 — Connect
Point us at your CCTV (RTSP/ONVIF). Hand out the app. Video never leaves the plant.
- 02 — Walk the site
EHS and ops teams walk the plant with the app to map cameras, define zones, and tune detections.
- 03 — Climb the ladder
Wave 1 capabilities go live in days. New duties unlock when the floor earns them.
See it on your site's cameras.
30-minute call, working pilot in two weeks — on your CCTV, your phones, your real risks and your real lines.