The Challenge
Enhancing Safety Across Multiple Facilities
In today's high-velocity food processing and distribution environments, Tyson Foods
faced a critical safety challenge: protecting workers and equipment across multiple
large-scale facilities where pedestrians and heavy machinery frequently interact. The
traditional approach of relying solely on operator vigilance and administrative controls
was insufficient for Tyson's commitment to workforce safety.
Challenges:
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High-risk interactions between personnel and forklifts
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Diverse facility layouts and operational patterns
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Loading dock hazards during trailer operations
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Need for real-time intervention capabilities
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Integration with existing CCTV infrastructure
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Consistent performance across multiple sites
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Balance between detection accuracy and false alarms
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Ensuring worker privacy while maintaining safety
The Solution
WARNY Optical Intelligence Solution
Bigmate's WARNY system was implemented to provide comprehensive safety monitoring and
alerts across Tyson's distribution centers. The solution focused on three critical
use cases: person-forklift proximity detection, person-truck interaction
monitoring, and trailer safety monitoring at loading docks. By processing all
detection at the edge, WARNY delivers real-time alerts without relying on cloud
connectivity.
Key Features of WARNY:
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Edge-Based Computer Vision Analysis
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Configurable Safety Zones
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Integration with Physical Alarm Systems
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No outbound network dependence
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Multi-Level Alert System (High/Medium/Low)
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Existing CCTV Camera Compatibility
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Privacy-Preserving Personnel Detection
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No wearable devices required
Overcoming
Implementation Challenges
The multi-site deployment presented several significant challenges that required
innovative solutions. Ensuring AI consistency across diverse environments, integrating
with existing infrastructure at scale, and developing customized safety rulesets for
each facility required careful planning and execution.
Key Implementation Challenges:
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Environmental Consistency: Rather than training
separate AI models for each facility, Bigmate used WARNY' generalized
detection system capable of adapting to various environments.
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Integration Scale: The WARNY system was
designed to work with standard CCTV cameras, requiring only the addition
of edge computing units at each facility, minimizing installation costs
while maximizing use of existing infrastructure.
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Customizable Rule Implementation: WARNY's
advanced safety zone and configurable ruleset functionality allowed for
tailored implementation at each site.
