Industrial Safety
Transforming Lockout/Tagout Safety with AI Vision & Industry 5.0 Intelligence
Overview
Lockout/Tagout (LOTO) is one of the most critical safety procedures in industrial environments. However, traditional LOTO gates depend on manual checks, physical locks, tags, and human supervision — leaving room for error and unsafe reactivation of machinery. Flagman's AI-Powered LOTO Gate Safety Solution modernizes LOTO protection with Industry 5.0 intelligence, using your existing IP cameras to create a fully automated, human-centric safety shield around high-risk maintenance zones. With facial recognition access control, real-time people counting, line-crossing analytics, and seamless PLC/SCADA integration, Flagman ensures zero unauthorized access and zero unsafe reactivation — even in the most demanding industrial environments.
The Challenge
During servicing, repairs, inspections, or maintenance, even a single unauthorized person entering a LOTO zone — or one supervisor assuming 'everyone is out' — can trigger catastrophic outcomes, including: accidental machine energization, hazardous movement of rotating or pressurized equipment, undetected individuals still inside the danger zone, and failure to follow documented LOTO compliance procedures. Manual LOTO processes are vulnerable to human error, especially across shifts, busy maintenance windows, and large industrial areas.
Key Challenges
- Accidental machine energization during maintenance
- Undetected personnel inside danger zones
- Manual check vulnerabilities across shifts
- LOTO compliance documentation gaps
Flagman Solution
Flagman converts your existing IP cameras into a high-precision LOTO gate monitoring system that ensures no machinery can be reactivated until every person has safely exited the zone and access is restricted to verified, authorized personnel only. The system combines facial recognition-based access control, line-crossing algorithms for personnel tracking, live inside-zone occupancy tracking, automated machine deactivation via SCADA/PLC, and instant alerts for violations or breaches.
Key Features
- Facial recognition access control for authorized personnel only
- AI-powered line crossing detection with accurate occupancy tracking
- Real-time inside-zone people monitoring
- Integration with existing IP cameras
- SCADA, PLC, and machine safety integration
- Automated alerts for unauthorized entry and gate breaches
- Centralized dashboard with time-stamped audit logs
Benefits
Eliminates Human Error in LOTO Procedures
Automated counting and access control remove manual check vulnerabilities, ensuring zero unauthorized access and preventing accidental machine activation.
Strengthens LOTO Compliance
Supports OSHA, ISO 45001, and internal safety SOPs with evidence-based logs, video records, and comprehensive audit trails.
Uses Existing Infrastructure
Leverages your current IP camera network with minimal costs and fast deployment, making it a cost-effective Industry 5.0 upgrade.
Frequently Asked Questions
Yes. The system is designed to integrate seamlessly with your current camera infrastructure without hardware changes.
Yes. All detection, counting, and safety actions run on the edge device even without internet connectivity.
Absolutely. Through PLC/SCADA integration, Flagman can prevent machine activation or force a shutdown in real time.
Flagman uses advanced line-crossing and occupancy algorithms designed for industrial movement patterns, ensuring high accuracy even in complex environments.
Yes. The system is trained to recognize faces with helmets, masks, and other PPE.
Flagman supports OSHA lockout/tagout requirements and provides the evidence/logs required for audits and compliance checks.
Yes. Entry/exit logs, occupancy counts, video snapshots, and breach alerts are all stored for audits and internal reporting.
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.
