Industrial Safety
AI-Enhanced Access & Intrusion Safety for Industry 5.0 Machines
Overview
Industrial machines—presses, CNCs, injection molding units, shearing machines, robotic arms, high-speed cutters, packaging machines, and automated assembly stations—pose constant risks when operators or unauthorized personnel enter hazardous zones at the wrong time. Traditional guarding methods such as fences, doors, interlocks, and warning labels provide only partial protection. They rely on human discipline and cannot prevent unauthorized access, accidental entry, intrusion during machine motion, or bypassing of physical guards. Flagman's AI-Powered Machine Guarding System introduces a new layer of Industry 5.0 intelligence, creating virtual safety zones, monitoring access in real time, and integrating facial recognition and automated stoppage to ensure only the right people operate the right machines at the right time.
The Challenge
Physical guards alone are no longer enough to protect operators or comply with modern industrial safety expectations. Key risks include:
Key Challenges
- Operators reaching into danger zones during machine motion
- Maintenance personnel entering without lockout procedures
- Workers bypassing fences or interlocks
- Visibility issues around large or enclosed machines
- No system to enforce authorized access
- Need for rapid-stop capability to avoid serious injury
Flagman Solution
Flagman creates virtual safety boundaries around hazardous machines, continuously analyzing entry into danger zones, human presence in restricted areas, operator posture and movement, machine accessibility points, and authorized vs. unauthorized personnel. When a violation is detected, Flagman issues immediate audio-visual alerts, sends stoppage or hold signals to the machine via PLC/relay, validates operator identity using facial recognition, logs the incident for compliance, and supports safe reactivation only after zone clearance. Flagman's virtual guarding eliminates the limitations of physical-only guarding systems.
Key Features
- Virtual zone configuration for hazard areas with independent sensitivity
- Real-time intrusion detection for dangerous zones and unauthorized entry
- Automated machine stoppage via PLC and safety relay integration
- Facial recognition access control with audit-ready trails
- PLC/SCADA integration for machine halt and alarm notifications
- Central logging with timestamps and video evidence for compliance
Benefits
Reduced Downtime
Automated stoppage before incidents escalate prevents false alarms while maintaining safety, minimizing unnecessary production interruptions.
Improved Accountability
Facial recognition and access logging ensure only authorized personnel operate hazardous equipment with complete, audit-ready access trails.
Stronger Safety Compliance
Evidence-based logging supports ISO, OSHA, and internal safety audits with automated enforcement and comprehensive event documentation.
Lower Probability of Injuries
Prevention of zone intrusion through real-time detection and automated response significantly reduces severe injury risks.
Enhanced Operator Confidence
Workers feel safer near guarded machines knowing intelligent systems are continuously monitoring for their protection.
Retrofit-Ready Solution
Industry 5.0-aligned machine guarding that blends AI with physical protection, ready for existing machines without major modifications.
Frequently Asked Questions
Using the Flagman dashboard to draw hazard zones.
Yes — via relay or PLC integration.
Yes — encrypted and access-controlled.
Yes — Modbus, ProfiNet, relay I/O.
Alarms sound, stops are triggered, logs are recorded.
Yes — detection parameters can be configured.
No — fast, low-impact retrofit.
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.
