October 2025

How A Manufacturing Company Cut Safety Incidents by 40% in Less than 6 Months

After struggling with poor PPE compliance & increasing safety violations across their production floors, this manufacturing company transformed their safety culture through behavior-based monitoring and real-time intervention systems.

Company

Industrial Manufacturing Corp

LOCATION

Ohio, USA

Industry

Heavy Manufacturing & Metal Fabrication

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Safety Impact In Numbers

We help manufacturers #AutomateSafety, #BoostProductivity, and #ReduceCosts with behavior-based safety solutions

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40%

reduction in reportable safety incidents

53%

improvement in overall PPE compliance

25%

increase in employee productivity

92%

PPE compliance rate achieved across all equipment

84%

reduction in restricted area violations

$650K

annual cost savings from reduced incidents

Challenges

Problem Statement

Manufacturing team was only addressing safety issues reactively after incidents occurred. PPE compliance was inconsistent across shifts with only 60% usage rates. The company had no real-time way to detect safety violations, restricted area breaches, or monitor critical behaviors like proper mask usage and glove compliance. The EHS team was struggling to maintain visibility across 450 employees and couldn't correlate safety performance with productivity metrics.

Solutions

Solutions Implemented

Behavior-based safety monitoring system was deployed using existing infrastructure with smart PPE tracking. The team configured:

  • PPE compliance monitoring (helmets, gloves, safety shoes, protective clothing)
  • Real-time behavioral observation for restricted area violations
  • Smart tracking for mask usage and SCBA requirements
  • Integration with productivity systems for performance correlation
  • Digital safety dashboards + recognition programs across all shifts
Results

The Results

Behavior-based safety system transformed workplace culture and operational performance. Key outcomes included:

  • Critical safety behaviors were now monitored 24/7 with immediate feedback.
  • Real-time alerts allowed supervisors to correct violations before incidents.
  • Safety-productivity correlation drove employee engagement and accountability.
  • Manual incident reviews dropped from 15+ hours/week to under 5 hours/week.
  • Culture improved with positive reinforcement replacing punitive approaches.
Testimonial

We went from reacting to incidents to actively preventing them using real-time insights. ObserviaAI was an eye opener for us.

Rune Arneberg

Warehouses Safety Lead

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