Case Study: Enhancing Safety & Productivity for a Leading Manufacturer

Industry: Manufacturing

🧩 Challenge

A leading laboratory infrastructure manufacturer sought to enhance employee safety and productivity within its production facilities.Key issues identified included:

• High particulate matter concentration in certain factory zones

• Elevated noise levels impacting workforce comfort and safety

• The need for data-driven insights to optimize environmental conditions

• Air quality concerns in the welding area

💡 Ai-DEA Labs’ Solution

Ai-DEA Labs delivered a comprehensive solution combining Particulate Matter Sensors, Noise Sensors, and Indoor Air Quality (IAQ) monitoring devices integrated into the customer’s internal servers.

This setup ensured real-time visibility into the factory’s environmental conditions while maintaining strict data privacy and security controls.

Key Features Delivered:

• Continuous monitoring of PM2.5, PM10, Temperature, Humidity, TVOC, and Noise levels

• Air Quality Index (AQI) monitoring as per CPCB compliance

• On-premise installation on customer’s local servers

• Custom dashboards for the factory, R&D center, and corporate office

• Configurable thresholds and zone-based alerts

• Data analytics identifying patterns of high particulate or noise exposure

• Historical trend data and automated report generation

  
  

⚙️ Implementation

• 10 person-days of site study and planning

• 15 monitoring devices with around 100 sensors deployed across key zones

• Project completed within two months 

• System live and running successfully for over two years, now under annual maintenance contract

  
  

🚀 Results & Impact

• Improved workplace safety: Identified and corrected high particulate zones making both factory environment and adjacent community safer to live

• Noise control: Mapped noisy areas and implemented ear protection recommendations

• Productivity gains: Healthier air quality and reduced fatigue among employees

• Continuous Indoor and Outdoor AQI monitoring

• Data-driven insights: Two years of operational data enabling predictive maintenance and compliance tracking

• Continuous corporate visibility: Real-time monitoring at factory, R&D, and company Corporate office

  
  

📊 Key Takeaway

Through smart deployment of our monitoring solution, Ai-DEA Labs empowered the manufacturer with quantitative, actionable intelligence to improve worker safety, environmental compliance, and operational excellence — setting a new standard for connected industrial environments.