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A system that enables monitoring and analysis of everything moving in the area and continuous ergonomic assessment of body posture and movement for workers in the area
About
The goal is to pilot a new state-of-the-art factory monitoring system that uses off-the-shelf security cameras around a pilot area at a processor where people are working to support process workflow analysis. The system will enable monitoring of everything moving in the area as well as the integration of technology with the ability to perform automatic and continuous ergonomic assessment of body posture and movement for the workers in the area.
This proposed pilot will enable the following value:
- Job identification and duration
- Staffing utilisation
- Throughput analysis and takt time from time series data
- Process flow and inventory analysis
- Scheduling analysis from the data
- Ergonomics and safety of the personnel working in the area (repetitive body motions including bending and twisting) from camera feeds to identify the joint angles of production personnel in real-time and alert awkward positions that may cause injury risks
- Digital twin analysis from simulated and actual data to improve operational efficiencies
- Signal processing and communication between the monitoring system and machine control to improve safety
The system could be deployed at a number of points along the red meat supply chain (lairage, slaughter, chilling, grading/boning, packaging).
This project aims to leverage from CSIRO technologies that have been developed for different fields and combine them for application at a red meat processor.
3D situational awareness (3DSA) is an innovative technology that uses security cameras to provide both real-time 3D situational awareness and factory or plant flow analytics. It is a scalable and cost-effective solution initially developed for distribution centres, warehouses and factories that works independently, and in conjunction with other systems like LiDAR, to provide unmatched insights into flow, productivity, efficiency and safety. 3DSA is an invaluable tool for equipping your business for its Industry 4.0 journey. Red meat processing facilities are becoming increasingly complex as busy 'cobotics' scenarios, where automated machinery, people, product and other tools combine with complex processing, product tracking and regulatory compliance systems. More complex environments in the facility have increased safety risks. Overhead objects and wet areas present a challenge, as do manual handling, repetitive tasks, tasks that require attention to detail, and strict hygiene and sanitation guidelines and procedures for food safety. Increased demand and global competitiveness, empowered by advancements in technology, are challenging businesses to rethink traditional operations to optimise for speed, efficiency and economy. 3DSA offers a scalable option for de-identified people safety, product and machinery flow, and early plant fault detection.
Find out more about the 3DSA technology:
- https://research.csiro.au/robotics/3d-situation-awareness/
- https://www.youtube.com/watch?v=-RCaDGOD1q8
Ergomechanic is a system that measures how your body moves and is loaded during work, sports, or lifestyle activities. It uses any type of camera as a 3D movement sensor and provides feedback on the amount of load your body has experienced in a day or over a week.
For industrial workers, correct physical motion of the body is needed to optimise performance and avoid injury. Measuring motion and monitoring the body’s feedback usually means intrusive sensors or uncomfortable wearables that may not have the resilience for a full day’s work.
Combining computer vision technology with physics-based biomechanical models, Ergomechanic is an effective, easy-to-use solution for identifying risky movement, optimising outcomes for workplace safety.
It does not record anything else about you, your appearance, or the nature of your activities. Our evidence-based system helps you understand:
- which parts of your daily activities could lead to injury in the long term
- how you could perform better physically
- how your environment could be improved to reduce injury risk.
Find out more about the Ergomechanic technology:
Key Benefits
This proposed solution will support the following capabilities for a facility wide system:
- Real-time localisation of machinery, product and anonymized staff in the environment
- Plant state – Identify and track position of product, machinery and tools in the pilot area
- Identification of specific image streams carrying high value information about humans performing assigned tasks
- Digital twin analysis from camera images on content of work and helpful online messages that can be initiated to production staff
- Analysis against ISO standards for static loads and online reporting on conformance using existing Ergomechanic functionality (i.e. dashboard and result recording)
- Development of new functionality assessing worker movement against ISO standards for dynamic movement and online reporting on conformance.
Applications
Red meat processing plants, factories, warehouses, Defence, mining