Connected Worker Platform for Real-Time Hazard Detection and Communication
Industry Industrial & Manufacturing
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$10B+ Client Revenues
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12+ Successful Years
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1000+ IT Ninjas
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5000+ Projects
Client's Testimonial
The solution from Developers.dev has fundamentally changed our approach to worker safety. Their ability to integrate sensor data, build a reliable backend, and deliver an app that works in a tough industrial environment was remarkable. The ROI in terms of safety incidents avoided has been immediate and significant.
Director of Factory Operations, Axiom Industrial
Client Introduction
A global leader in heavy machinery manufacturing (>$1B ARR) sought to improve safety across its sprawling factory floors. They wanted to equip their workers with a ruggedized wearable device and a companion app that could detect falls, monitor exposure to environmental hazards, and provide a "man-down" alert system.
Problem
The client was experiencing a high rate of safety incidents and slow emergency response times due to the noisy, complex environment of their factories. Traditional safety protocols were reactive, and they needed a proactive, technology-driven solution.
Key Challenges
Harsh Environment
The app needed to run on ruggedized hardware and function reliably amidst heavy machinery, dust, and intermittent connectivity.
Sensor Accuracy
The fall detection algorithm had to be highly accurate to avoid false positives from normal worker movements.
Real-Time Alerts
The alert system had to deliver notifications to supervisors within seconds of an incident.
Battery Life
The device and app needed to last through a full 12-hour shift without needing a recharge.
Our Solution
We deployed our "Embedded-Systems / IoT Edge Pod" to tackle this challenge. The team focused on creating a highly optimized Wear OS application and a resilient backend system.
⚙️ Advanced Sensor Fusion
We developed a sophisticated algorithm that fused data from the accelerometer, gyroscope, and barometer to detect falls with 99.5% accuracy, distinguishing between actual falls and actions like jumping or bending down.
🧠 Edge Processing
To ensure instant alerts even with poor connectivity, critical logic like fall detection was processed directly on the wearable (Edge AI). Alerts were then broadcast over a local mesh network if cloud connectivity was unavailable.
🔋 Low-Power OS
We created a custom, stripped-down version of Wear OS, removing non-essential services to maximize battery life, consistently achieving over 14 hours of operation.
📊 Centralized Dashboard
We built a web-based dashboard for supervisors showing real-time worker locations, status, and any active alerts, allowing for coordinated and rapid emergency response.
Implementation and Execution
Agile Methodology
Collaborated with the client's hardware partner to select the optimal ruggedized Android wearable.
DevOps Pipeline
Spent three weeks on-site at a pilot factory to gather data on worker movements to train the fall detection model.
User-Centric Design
Used a T&M model to allow for iterative development and refinement of the sensor algorithms.
Global Rollout
Built the backend on Azure IoT Hub for massive scalability and device management.
Comprehensive Training
Conducted extensive stress testing on the device's durability, connectivity, and battery performance.
Post-Launch Support
Rolled out the solution to 5,000 workers across three continents over a six-month period.
Positive Outcome
🛡️ 40% Reduction in Safety Incidents
In the first year of deployment, the client reported a 40% decrease in major safety incidents.
🚨 75% Faster Emergency Response
The average time to respond to a "man-down" alert was reduced from 8 minutes to under 2 minutes.
📈 Operational Efficiency Gains
The app's communication features also helped streamline daily operations, leading to an estimated 5% productivity increase.
🏆 Award-Winning Innovation
The client won a national industry award for innovation in workplace safety for the solution we helped build.
Why Choose Us
🏭 Expertise in Industrial IoT & Edge AI
🔬 Advanced Sensor Fusion Algorithm Development
🔋 Focus on High-Reliability, Low-Power Solutions
☁️ Scalable Cloud Backend Architecture (Azure IoT)
🛡️ Experience with Ruggedized Hardware
🤝 Agile, Collaborative Problem-Solving
👑 End-to-End Solution Ownership
💰 Clear, Measurable ROI
🎯 Commitment to Mission-Critical Performance
Conclusion
This project demonstrates our capability to move beyond consumer applications and deliver high-stakes, industrial-grade wearable solutions that protect lives and improve business outcomes in the most demanding environments.