Using Artificial Intelligence to Avoid Incidents - www.ussteel.com
In late 2021, a fatality occurred at one of our facilities that highlighted the pressing need to improve safety outcomes regarding high voltage electrical maintenance across all of our plants. Recognizing the urgency, we forged a partnership in 2022 with a company dedicated to developing innovative AI-based solutions for transforming worker safety, productivity, and well-being. The solution utilizes real-time video footage from worksites, coupled with AI models that monitor and guide workers towards safe and productive outcomes.
Long before partnering with this vendor, we conducted arc flash studies and implemented a comprehensive electrical safety program which included electrical personal protective equipment (PPE) requirements. This data served as the foundation for training the AI models.
In 2023, we began evaluating the feasibility of this technology in addressing the challenges identified when a field trial was initiated at one of our plants. The trial encompassed multiple stages, progressing from simulated workspaces to live deployment in an active motor control center (MCC) within one of our departments.
Thirteen strategically positioned cameras were installed in the MCC to ensure comprehensive coverage of the work area, capturing real-time video footage of worker activities 24/7. Using this video data, the AI models were trained to identify various approved PPE, including the accurate detection of PPE presence or absence despite variations in age, cleanliness, and other differences. To challenge the accuracy of the AI model, workers intentionally wore incorrect PPE in controlled environments that could potentially confuse the identification of correct PPE.
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The AI model was further trained to recognize the initiation of work or the intent to work by workers, based on typical trigger actions such as opening electrical panel doors or specific body and arm orientations. Once work was identified as having begun, the AI solution automatically checked if the worker was wearing the appropriate PPE based on the type of equipment being handled. If unsuitable PPE was detected, a voice alert immediately instructed the worker to halt work and guided them towards the correct PPE required. If a worker persisted in working without suitable PPE, a notification was sent to a supervisor through a mobile app.
The mobile app for the AI solution also presented analytics to enhance visibility and provide teaching moments during safety talks and reviews. These analytics provided valuable insights for discussions on improving safety practices, allowing for a proactive approach to preventing incidents and enhancing overall worker safety.
By leveraging AI-powered video analysis, real-time alerts, and comprehensive analytics, we鈥檙e seeing the potential to enhance worker safety, optimize productivity, and promote a culture of continuous improvement within our facilities. This partnership exemplifies our commitment to prioritizing the well-being of our workforce and creating safer work environments in our industry.
Interested in learning more about safety advances and technology? Listen to our Steel Stories by U. S. Steel podcast, 'From Hard Hats to Smart Hats: The Future of Steelworker Safety with Doug Matthews of Guardhat.'
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