Manufacturing Video Analytics That Keeps Every Shift Safe and Audit-Ready
Agrex turns the CCTV already in your plant into a 24/7 safety, compliance and efficiency system — PPE, restricted zones, forklifts, gates and lines. No new cameras. Live in under 30 days.
Your factory inspector visits once every three years. Your cameras are there every shift.
Indian factories are among the most dangerous workplaces in the world, and inspection capacity has not kept up. Manufacturing video analytics fills that gap: continuous, evidence-backed monitoring of the zones and behaviours that cause injuries, recalls and audit failures — on the CCTV you already own.
Video analytics for manufacturing, zone by zone
Every plant zone gets its own rules — paint shop, press shop, packing line, yard. Your EHS lead draws the zone and sets the rule; no developer required.
Worker safety & PPE
The violations that cause injuries, caught in the moment and routed to the person who can stop them.
- Helmet, vest, goggles, gloves, boots, respirator — per zone, per shift
- Restricted-zone entry near presses, robotic cells, furnaces
- Forklift / MHE in pedestrian aisles, speed and near-miss
- Fall, collapse and lone-worker detection
- Fire, smoke and blocked-exit alerts
up from 64%
Compliance & audit evidence
Timestamped video for every event, so audits stop depending on paper logs and walk-throughs.
- Shift-level compliance scores by zone and contractor
- Detected → acknowledged → actioned → resolved on every alert
- 30-day exports for OEM, ISO 45001, IATF 16949 audits
- SOP checks: gowning, hygiene, LOTO, hot-work fire watch
- Supervisor-presence verification in hazardous zones
not a weekend
Production efficiency
See the line the way your plant head wishes they could — every station, every shift, without walking it.
- Line stoppage detected in seconds, not at shift review
- Machine and worker idle time by station
- Cycle-time and bottleneck heatmaps
- Pathway compliance and material-flow deviations
- Opening / closing and shift-handover checks
−18% cycle time
Gate, yard & security
From the boom barrier to the after-hours perimeter — who and what moved, and when.
- ANPR at gates: vehicle turnaround time = exit − entry
- Truck dock-in / dock-out timestamps
- Random parking of BOPT, pallet jacks and trucks
- After-hours intrusion and perimeter breach
- Camera health: tampering, blind feeds, retention
Indian plates
Same cameras. Different rules for every plant type.
A paint shop, a clean room and a cement kiln don't share a rulebook. Pick your sector to see what Agrex monitors and the numbers it moves.
Press shops, paint shops and robotic cells — where the injuries happen
What Agrex watches
- Zone-specific PPE: paint = suit + respirator, weld = shield + gloves
- Exclusion zones around active presses and robots
- Machine-guard removal and bypass
- Line stoppage, cycle time and idle-station alerts
- Forklift ↔ pedestrian separation in logistics bays
- IATF 16949 / ISO 45001 evidence, continuously
Regulation: Factories Act 1948 · OSH Code 2020 · IATF 16949 · ISO 45001 · AIS-156 (EV battery assembly)
Hygiene SOPs on every shift, not just on audit day
What Agrex watches
- Masks, gloves, hairnets, aprons at every zone entry
- Handwashing compliance at wash stations
- Allergen / halal zone movement and changeover cleaning
- Cold-room door-open time and dock temperature zones
- Foreign-object risks: jewellery, uncovered hair, open packaging
- FSSAI / HACCP / BRC audit-ready reports
Regulation: FSSAI Schedule 4 (GMP/GHP/HACCP) · FSSC 22000 / BRC for export · OSH Code 2020
Gowning, airlocks and batch SOPs with unfalsifiable video evidence
What Agrex watches
- Gowning sequence verification before clean-room entry
- Airlock interlock and graded-zone flow (D → C → B → A)
- Re-gowning after breaks and exits
- Quarantine-area access and material-handling SOPs
- Fire, smoke and blocked exits in solvent stores
- Timestamped records aligned to ALCOA+ and 21 CFR Part 11
Regulation: Revised Schedule M · US FDA 21 CFR Part 11 · WHO-GMP · CDSCO inspections
Confined spaces, cranes, conveyors and dust zones — monitored 24/7
What Agrex watches
- Heat-resistant suit, face shield, respirator and hearing PPE by zone
- Crane swing-radius and exclusion-zone intrusion
- Confined-space entry, buddy system and dwell time
- Conveyor pinch-point proximity and LOTO compliance
- Harness use at height, scaffolding overcrowding
- Truck-yard ANPR, speed and pedestrian separation
Regulation: Factories Act 1948 (fencing of machinery) · OSH Code 2020 · ISO 45001 · PESO where applicable
Hazardous zones, hot-work permits and spills — seen in seconds
What Agrex watches
- SCBA, chemical suits, gas masks and face shields in Zone 0/1/2
- Hot-work zones and fire-watch presence during and after
- Confined-space entry and lone-worker distress
- Spill detection and tanker loading SOPs
- Emergency-shower / eyewash access, blocked exits
- Muster-point headcount during evacuation
Regulation: PESO · Factories Act hazardous-process provisions · OSH Code 2020 · ATEX zoning
Clean-room gowning, ESD discipline and day-one safety for new fabs
What Agrex watches
- Bunny suits, shoe covers, masks, gloves at clean-room entry
- ESD wrist-strap use and EPA-zone access
- Chemical-handling PPE: HF, solvents, flux
- Ergonomic risk and fatigue on long assembly shifts
- Restricted access to hazardous-material stores
- Commissioning-phase safety rules before production starts
Standards: ISO 14644-1 clean rooms · ANSI/ESD S20.20 · OSH Code 2020
Talk to your plant cameras
Ask your EHS question in plain English and get an answer with the clips to back it up. Then let the agent chase the unresolved ones so your safety officers spend the week on the floor, not in spreadsheets.
Works with the cameras already in your plant
Hikvision, CP Plus, Dahua, Axis, Honeywell — any IP or analog camera, any NVR or VMS. Processing runs on an edge box inside your network, so video never leaves the plant.
Real detections from real plant floors
These are actual frames from Agrex deployments — not renders. Every alert carries the zone, the confidence, the time and who it was raised to.
- PPE, zone and forklift alerts with video evidence
- Escalation chain: supervisor → plant head → corporate EHS
- Vehicle TAT and dock timestamps from ANPR
- Works on the messiest camera estate in your network
How a leading manufacturer took PPE compliance from 64% to 91%
Existing cameras, no new hardware, results inside two quarters.
The challenge
Supervisors could not watch every zone on every shift. PPE compliance sat at 64%, forklifts shared aisles with people, and package mishandling at the dock was found after the damage, not during it. Audit evidence lived on paper.
What Agrex deployed
- PPE compliance — face shields, goggles, gloves, masks and safety shoes by zone
- Forklift & human pathway safety — vehicles in pedestrian aisles, blocked routes
- Random parking detection — BOPT, pallet jacks and trucks outside designated bays
- Opening / closing & dock time — automated timestamps, no manual entry
- Idle time & activity — machine and worker inactivity alerts
- Package handling — throwing and damaged-box detection at loading
Results
Why it worked
Nobody added cameras or hired more auditors. The plant connected its CCTV to Agrex, drew its zones, and the alerts went to the people already on shift.
- Existing cameras became safety sensors
- Real-time alerts replaced weekly walk-throughs
- Every event logged with a clip for the audit file
- Escalation closed the loop without a human chasing it
“As an IT Manager, I value solutions that are powerful yet easy to integrate. Agrex.ai provided a scalable edge-AI solution that has enhanced our site visibility and security without requiring a total overhaul of our legacy systems.”
What one incident costs vs. what monitoring costs
Indian data, not global averages. Most multi-plant deployments pay back inside two quarters.
The cost of not watching
Direct plus indirect cost per event, India
What Agrex returns
10-plant, 500-camera enterprise model, annual value
Typical plant: 30–100 cameras. Pilot on one plant in under 30 days; enterprise programmes replicate the same architecture plant by plant.
Ready to make every shift safe and audit-ready?
Run a 30-day pilot on the messiest camera estate you have. If Agrex handles that plant, it handles all of them.
Tell us about your plant
Our team replies within 2 hours on working days.
Schedule a plant walkthrough
30 minutes with a manufacturing specialist — bring your camera list and your top three hazards.
Manufacturing video analytics, answered
The questions plant heads, EHS leads and IT managers ask before a pilot.
Manufacturing video analytics is AI software that analyses CCTV feeds from factory floors, production lines, gates and yards to detect safety violations, SOP deviations and process events automatically — PPE compliance, restricted-zone entry, forklift proximity, line stoppage, vehicle turnaround — and route each event to the right person with a video clip. It runs on the cameras a plant already has.
Yes. Agrex connects to any IP or analog camera through RTSP/ONVIF and to your existing NVR or VMS — Hikvision, CP Plus, Dahua, Axis, Honeywell, Milestone, Genetec. Cameras in dust, heat, steam and low light are supported; the pilot usually starts on the plant with the most mixed camera estate to prove exactly that.
Yes. The Agrex Edge box runs inference on-premise, so raw video never leaves the plant. Only event clips and metadata are retained, encrypted with AES-256 under ISO 27001-aligned practices. Cloud or private-cloud processing is available where a plant prefers it.
Agrex’s video analytics for PPE compliance covers helmets, safety vests, goggles, gloves, boots, masks, face shields, respirators, gowns, hairnets and ear protection — with different rules per zone, so the paint shop, the press line and the packing hall each enforce their own kit. Compliance is scored per zone, shift and contractor, and a proven deployment moved PPE compliance from 64% to 91%.
Every event is recorded as detected → acknowledged → actioned → resolved with a timestamped clip, and compliance logs export by zone, shift and plant in seconds. That replaces paper registers and walk-through evidence for Factories Act inspections, ISO 45001 and IATF 16949 audits, and the supplier audits Tier-1 OEMs now run. Under OSH Code 2020 it also documents the occupier's continuous duty of care.
The first plant typically goes from camera review to live dashboards in under 30 days. Plants two to four replicate the same rules and architecture in two to three weeks each, and later plants in under two weeks. Agrex has onboarded 500+ locations in under four weeks on other rollouts.
Yes. 200+ pre-built models cover PPE, zones, forklifts, ANPR, fire and intrusion on day one. Plant-specific scenarios — a particular machine guard, a dust-zone rule, a cut-resistant glove — are trained from your own footage in 2 to 15 days.
Cost depends on the number of cameras, the use cases you switch on and whether you run on-premise or in the cloud; a typical plant runs 30–100 cameras. Against Indian incident costs — ₹10–30 lakh for a major injury, ₹15–40 lakh per hour of line stoppage — multi-plant programmes model a 3–7× annual return and pay back in 3–6 months. Ask for a budgetary quote for one pilot plant.
Manufacturing video analytics is AI software that analyses CCTV feeds from factory floors, production lines, gates and safety zones to monitor PPE compliance, detect safety violations and process deviations, and log every event with video evidence — across all shifts, on existing cameras, without new hardware.
Video analytics for manufacturing in India: what gets monitored
Indian plants face a specific combination: high injury rates, sparse inspection, new criminal liability under the OSH Code 2020, and customers who now audit suppliers harder than the regulator does. Agrex manufacturing video analytics addresses all four from the camera estate already installed — a segment that makes up 28.75% of India's CCTV market. See also logistics video analytics for warehouse and dock operations that sit alongside the plant. Agrex is on-premise AI video analytics for manufacturing — inference runs on an edge box inside the plant network, so raw video and models never leave the building.
Key manufacturing video analytics use cases
- PPE compliance: helmet, vest, goggles, gloves, boots and respirator detection per zone and shift
- Restricted-zone and machine-proximity alerts around presses, robotic cells and furnaces
- Forklift and MHE safety: pedestrian-aisle intrusion, speed, near-miss and random parking
- Production line monitoring: stoppage, idle time, cycle time and pathway compliance
- Gate and yard: ANPR vehicle turnaround time, dock-in / dock-out, after-hours intrusion
- Audit evidence: detected → acknowledged → resolved logs exportable by zone, shift and plant
Agrex integrates with existing CCTV, NVR and VMS infrastructure, runs on an on-premise edge box so video stays inside the plant network, and includes camera health monitoring so feeds stay live across every shift.
Last updated: August 2026 · Published by Agrex.ai