Manufacturing & industry · Automotive
Robot cells and forklifts, enforced every shift.
Plants, paint shops, and service bays mix people, robots, and vehicles. Camnitive watches robot cells, forklift traffic, PPE, and stopped stations on your existing cameras. Every exception comes with evidence.
In automotive
What goes wrong today.
Robots, forklifts, and people in one hall
Robot cells, tuggers, and forklifts work beside people on foot, and guarding has gaps that nobody watches between audits.
Every minute of a stopped line costs
A station left without an operator or a starved line is often noticed only when the next station runs dry.
Audits want proof, not checklists
OEM, supplier, and safety audits ask for evidence of PPE and zone discipline that paper rounds cannot give.
Detect · Step 1 of 4
What the cameras watch for.
Runs on the plant network beside your guarding and PLCs, with optional outputs as an aid next to certified safety systems.
Sealed evidence
Ostmere Foods Packing Plant
Demo footage, annotated the way FloFrame does. Each card appears as its alert is raised.
Robot & machine cells
People inside a guarded cell during a cycle. An aid next to your certified guarding.
PPE compliance
Hard hats and vests in body-shop, logistics, and paint-shop zones that require them.
Forklift proximity
Alerts when people come within set distances of moving forklifts and tuggers.
Vehicle movement
Speed and routes of finished vehicles in yards, test areas, and service bays.
Line stoppages
Stations left without an operator past takt time, flagged the moment they stop.
Three-point contact
Posture rules on cab steps, ladders, and mezzanine stairs.
Rules
Rules you would run.
Written in plain words, run on site, checked by a vision model before anyone is alerted.
Robot cells
“No one inside Weld Cell 3 while the robots are running”
Then: STACK LIGHT ON · CLIP SEALED ✓
Open in the Rule PlaygroundForklift proximity
“No person within 3 m of a moving forklift in logistics aisles”
Then: SUPERVISOR PAGED · NEAR MISS LOGGED
Open in the Rule PlaygroundLine stoppages
“Alert when Station 14 has no operator for longer than 90 seconds”
Then: LINE LEAD NOTIFIED ✓
Open in the Rule Playground
Measure · Step 2 of 4
Every alert becomes a number you manage.
What FloFusion measures for Automotive, per zone, per site and over time.
Line staffing
People at each station and bay, against the crew the line was planned for.
Time at station
How long operators stay at each station, and where stations sit empty.
Guard-zone near misses
Reaches into guarded zones while the line runs, per hour watched.
What a pilot sets out to move
- more near misses surfaced
- 3–5×
- typical pilot target on covered aisles
- to flag a stopped station
- Seconds
- pilot target, not at the end of the shift
- fewer cell-entry events
- 30–50%
- typical pilot target during active cycles
Pilot targets agreed with you up front, not past results.
Comply · Step 3 of 4
Proof that holds up with auditors.
The rules that apply to Automotive, scored continuously from camera evidence, with a signed record anyone can verify.
EU AI Act
AI used for workplace monitoring and safety is high-risk: you must run risk management, keep event logs, maintain technical documentation, and guarantee human oversight and accuracy monitoring.
EU OSH Framework Directive
Employers carry a general duty to prevent occupational risks and demonstrate systematic prevention measures.
UK GDPR and Data Protection Act 2018
Video of identifiable people is personal data: you need a lawful basis, transparency, data minimisation and retention limits, and a DPIA before systematic monitoring of staff.
ICO guidance on monitoring workers
Monitoring must be necessary, proportionate and open: tell workers what you monitor and why, consult them, choose the least intrusive means, and avoid covert monitoring.
Improve · Step 4 of 4
What to change next.
The process map shows where the line is short of hands and where people reach into moving parts.
Rebalance bays across shifts
Move an operator to the bays the map shows unattended at peak.
Guard the capper infeed
Add a fixed guard where reaches into the bottle stream repeat.
Examples of what a pilot’s process map points to.
Getting started
A pilot on the cameras you own.
Prove robot-cell, forklift, PPE, and stopped-station rules in one plant area or service centre.
Scope
- Robot and machine cells (people inside during an active cycle)
- Logistics aisles and line-side supply (forklift and tugger proximity)
- Body shop, paint shop, and logistics zones (PPE where required)
- Assembly stations (no operator past takt time)
We configure
- Plain-English rules per cell, aisle, and station, with shift patterns
- Proximity distances in metres for forklifts and tuggers
- Optional on-site outputs (HTTP relay modules, Modbus TCP to a PLC, stack lights) as an aid next to certified safety systems
- Routing to EHS, production, and maintenance, with sealed evidence on each event
You walk away with
- Near misses between people and forklifts surfaced per week
- Cell-entry events during active cycles, against a baseline
- Minutes of stopped stations caught by rule, per shift
- Audit-ready evidence for every PPE and zone exception
Questions
Automotive: common questions.
Does this replace our light curtains and safety PLCs?
No. Camnitive is an aid next to certified safety systems. It covers gaps in guarding, records what happened, and can drive a relay, Modbus TCP or MQTT signal as an extra warning.
Link to this questionHow does it catch line stoppages?
Line stoppage is a standard detection. A station left without an operator past its takt time, or a conveyor that goes still, raises an alert with the clip, and Insights measures the lost time.
Link to this questionCan it check three-point contact on cab steps and ladders?
Posture rules run on marked steps and ladders. We check them on your own cameras during the pilot before they go into routine use.
Link to this questionWe run several plants and dealer service centres. Can we compare them?
Yes. FloFusion groups sites by organisation and region, and Insights and Control Tower compare them on the same measures.
Link to this questionHow do supplier and brand audits fit in?
Packs score your clauses continuously, and each score is a signed, hash-chained snapshot. Share a link with an auditor, or share scores with a buyer by consent. Links carry records, not video.
Link to this questionDo we need new cameras or model training?
No. It works with your existing RTSP or ONVIF cameras. People, vehicles, PPE and line stoppages are standard detections, with no training on your site.
Link to this questionSee it on your own cameras.
A demo on footage from an operation like yours, then a pilot on the cameras you own.