Industrial Safety
AI-Powered Precision Safety for Industrial Machines — Designed for Industry 5.0 Human–Machine Coexistence
Overview
Industrial machines such as rollers, cutters, presses, guillotines, shearing machines, injection molding units, CNCs, and automated assembly equipment involve high-speed, high-force motions. Even a fraction of a second of misplacement can result in severe hand or finger injuries, often leading to permanent disability. Flagman's AI-Powered Hand & Finger Detection System brings Industry 5.0 intelligence directly to the machine, creating a smart "No-Hand Zone" around hazardous operating points. Through advanced AI vision and real-time machine-interlock integration, the system prevents accidental contact and makes human–machine interaction dramatically safer.
The Challenge
Hand and finger injuries are among the most common and severe incidents in industrial operations. Most occur during:
Key Challenges
- Loading/unloading material
- Clearing jams
- Manual adjustments
- Setup and calibration
- Routine maintenance
Flagman Solution
Flagman continuously monitors critical points on the machine—rollers, cutter lines, press zones, nip points, and rotating assemblies. The moment the AI identifies a hand or finger entering the hazardous region, the system instantly triggers machine stop or shutdown signal, activates audio-visual alerts, logs the event for audit and training, and prevents the machine from cycling until the area is safe again. Using the machine's existing camera positions (or compact AI cameras), Flagman creates a protective virtual boundary that requires no contact sensors, light curtains, or complicated wiring.
Key Features
- Precision hand and finger detection in hazardous zones
- Instant machine stop with PLC and relay integration
- Audio-visual alerts with sirens and LED warnings
- Compatible with Modbus, ProfiNet, and EtherNet/IP
- Retrofit-friendly for old and custom machines
- Offline AI processing for instant response
Benefits
Drastically Reduces Hand Injuries
Precision AI detection prevents hands and fingers from entering hazardous zones, eliminating reliance on human reaction time.
Strengthens Compliance
Provides audit-ready logs for investigations and helps meet OSHA/ISO standards with documented safety interventions.
Enhances Worker Confidence
Improves worker confidence and trust while supporting Industry 5.0 human–machine collaboration principles.
Improves Productivity
Prevents downtime from injuries while allowing operators to work safely around hazardous machinery without slowing operations.
Retrofit-Friendly Solution
Quick deployment with minimal modification makes it ideal for upgrades to existing machines and custom-built equipment.
Frequently Asked Questions
Rollers, cutters, saws, presses, and any equipment with pinch/crush hazards.
Models detect hands/fingers in real time, even during fast movements.
Calibration and validation logic minimize false triggers.
Using relay outputs or PLC communication integrated with safety circuits.
Yes — relay and PLC interfaces allow universal retrofit.
Yes — all safety logic runs on-device.
Periodic lens cleaning plus automated diagnostics.
Ready to Transform Your Safety Operations?
See how Flagman can help you achieve zero-harm operations with AI-powered safety systems. Our team will show you how this solution fits your specific environment.
