Development of IoT-Enabled Worker Safety Monitoring Platform for Industrial Environments

The client faces challenges in proactively monitoring worker health and safety in physically demanding environments such as industrial, emergency response, and defense sectors. Limited real-time visibility into vital signs like heart rate, body temperature, and fatigue levels hampers safety measures, leading to increased risk of heat exhaustion, fatigue, and related accidents. Existing systems lack seamless, immediate data collection and actionable insights, compromising worker safety and operational costs.

A mid-to-large manufacturing company specializing in heavy industrial production, with a focus on worker safety and operational efficiency in demanding work environments.

• Implement a cross-platform mobile and web application enabling real-time vital sign monitoring of industrial workers using wearable IoT devices.
• Enable safety managers to access aggregated and detailed health data, facilitating early detection of heat exhaustion and fatigue.
• Create secure user authentication, role management, and device connectivity features to ensure operational reliability.
• Achieve approximately 40% reduction in safety-related incidents and operational costs through early warning and proactive intervention.
• Deliver a validated proof of concept within a constrained timeframe and budget, supporting scalability and broader deployment.

• BLE-enabled mobile app for seamless pairing with wearable health monitors to receive live vital signs such as heart rate, body temperature, and sweat rate.
• Real-time data visualization to indicate safe or at-risk vital sign levels for individual workers.
• Historical data charts displaying parameters over adjustable time ranges (e.g., past 90 minutes) with live updates.
• Supervisor dashboard presenting aggregated team health metrics, individual connection statuses, and detailed time-based charts.
• Automatic reconnection logic to maintain data flow with wearable devices even after disconnections or application restarts.
• Device management allowing users to disconnect, scan for available devices, and reconnect to selected wearables.
• Secure login and user profile management supporting role-based access (worker, supervisor, safety manager).
• Battery level indicators for wearables to ensure uninterrupted operation.
• Team management features including user role assignment, team creation, and member management.
• Comparison tools for safety metrics across different teams to identify patterns or risk factors.

• Wearable health monitors via BLE for vital sign data collection.
• Secure user authentication systems (e.g., email/password).
• Backend systems for data storage, processing, and retrieval.
• Notification services for alerts on abnormal vitals.

• Real-time data updates with minimal latency (target <2 seconds).
• High system availability and uptime to support continuous monitoring.
• Data security and privacy compliance, supporting pseudonymized historical data analysis.
• Scalability to support increasing number of users and devices.
• Battery-efficient app operation, especially for background processes on iOS and Android.

This system is expected to significantly enhance worker safety by enabling proactive health risk detection, thus reducing heat exhaustion and fatigue-related incidents by approximately 40%. The solution will streamline safety management processes, reduce operational costs associated with accidents, and support broader deployment in high-demand environments. The proof of concept aims to validate technical feasibility and operational value within a limited timeframe and resource scope, paving the way for full-scale implementation and business growth.