Plant-floor cameras that see the aisle, the hatch and the exclusion paint

You already film the line, the forklift aisle, the confined-space hatch and the finished-goods store. Most of that footage is a record of what already happened. When the Factories Act, or ISO 45001 if you run it, asks who was in a dangerous place and when, you should not have to reconstruct it from a radio call.

Sentinel sits on those cameras so a body inside guarded paint while the machine is still live, or a forklift and a person sharing an aisle, becomes a page to the shift supervisor. The camera names the body. The PLC or interlock names the machine state. You still choose whether a line-stop wire exists.

A 30-day pilot sits on the feeds you already run. Video alone does not stop a line. The record of what happened sits on the plant network so the next toolbox talk is not guesswork.

1. A limb inside a guarded zone while the line is live

   When the camera sees a person in the exclusion paint and the PLC still reads energised, that is the event that amputates. The page can carry a line-stop signal if you have wired one. The camera cannot see a missing padlock. It can see the person standing where the machine state says nobody should be.

2. A forklift and a pedestrian sharing an aisle

   Most forklift fatalities involve a person on foot. Vision proximity is enough to start. A strobe or horn at the intersection, and a telematics flag if the truck reports one, turns a near-miss into a record instead of a rumour.

3. A hatch entered with no attendant in frame

   Confined-space work still kills people who went in alone. We watch hatch presence and whether an attendant is visible. We cannot measure gas. The detector does that, and we confirm who entered.

4. Smoke in packaging or a dusty hall

   Steam and dust fool a video-only smoke flag. Where you have a detector, we join the two. A video-only flag in a steam-heavy hall stays at a low tier so the shift does not learn to ignore it.

5. Missing kit on the line

   A person without the hi-vis, hearing, eye or foot protection the zone requires becomes a leading-indicator ticket, not a surprise in next month's audit.

6. Someone in the finished-goods store after hours

   A person in the store or yard outside shift, or a door left open on a cage, is a chain-of-custody gap. The camera does not name a thief. It names a body where the store should be empty.

7. Something left in a fire-exit lane

   A pallet or a vehicle parked in marked egress turns every other incident into a worse one. An unattended-object check on those lanes is a simple rule with a clear cost.

8. A camera that has been moved or blinded

   When the overhead lens over an exclusion zone goes dark, you have lost the only frame that would have joined the PLC bit. That is the alarm.

A person in an exclusion zone is a camera event. A machine that is still energised is a PLC event. Neither sentence is enough on its own. Sentinel reads interlocks, isolation status where it is instrumented, door contacts, forklift telematics and smoke detectors.

A person in the paint plus a PLC that reads energised is a high-confidence unsafe event. Telematics over-speed plus a pedestrian in frame is a verified near-miss. Video alone does not stop a line. You choose whether that wire exists.

A plant does not need a new camera estate. It needs a loop the shift can trust: baseline the zones you already painted, watch them, confirm with the PLC when the machine state matters, then log what happened so the next toolbox talk is not guesswork.

1. 01 Baseline

   We sit on the cameras and the zones you already have: exclusion paint, hatch, aisle and store.

2. 02 Watch

   Security, operations and HSE packs read every attached feed for the shift.

3. 03 Confirm

   A person in a zone plus a PLC or interlock bit is the high-confidence event. Review is optional for recordables.

4. 04 Intervene

   Supervisor page, strobe, or a line-stop signal if you have chosen to wire one.

5. 05 Log

   The frame, the zone and the machine state sit on the plant network.

6. 06 Review

   Leading indicators for the next ISO 45001 conversation, not a surprise in an audit.

The appliance sits on the plant OT network. Line-stop, if you want it, needs on-site inference. Air-gapped is supported. Raw video stays on site.

Can you stop a line on zone entry?

Yes, via a PLC signal when a person is in the exclusion zone and the machine is still energised. Video alone does not stop a line. You choose whether that wire exists.

Does this produce ISO 45001 leading indicators?

Yes. Confirmed PPE gaps, proximity events and exclusion-zone entries become structured records a safety meeting can actually use.

Does forklift safety need wearable tags?

No. Vision proximity is enough to start. Forklift telematics is an optional extra, not a prerequisite.

What about dust and steam?

Models are tuned against steam and dust, and fused with a detector where one exists. A video-only smoke flag in a steam-heavy hall stays at a low tier.

How do you treat confined space?

Hatch presence plus attendant presence, and permit reading when a permit is actually in the frame. We cannot measure gas. The detector does.

Where does footage live?

On the edge appliance. Air-gapped is supported. Only events, metadata and clips you consent to ever leave.