How a leading steel maker used virtual geofencing and PLC integration to eliminate risk
With Everguard.ai, a leading US steel manufacturer created a virtual safety zone around high-risk equipment. Now, when a worker enters without proper shutdown, the system automatically powers off the machine—protecting people and reinforcing a culture of safety.
Problem to solve:
A leading manufacturer had an ongoing problem despite implementing protocols and training. They require workers to shut down wrapper equipment at the operating table and take the key with them before entering the hazardous area. However, this step is sometimes missed. A worker doesn't take the key with them when stepping into the wrapper area. Other workers can unknowingly power on the equipment while someone was still inside—creating a serious risk of injury.
How we solve
Everguard.ai’s computer vision creates a virtual geofence around the wrapper equipment, detecting when a worker enters the zone and verifying whether the machine has been properly shut down. If not, the system uses PLC integration to prevent the equipment from being powered on while a worker is inside the geofenced area. This real-time, automated enforcement adds a consistent and fail-safe layer of protection.
We see great opportunities for Everguard here. The team is easy to work with and we see ourselves investing more in this type of technology in the very near future.
Safety manager, Leading steel manufacturer
Key results
- Zero safety incidents related to wrapper equipment since implementation
- Improved worker confidence and safety culture on production floor
- Seamless PLC integration
- Actionable insights and training materials from user portal
Conclusion
By combining AI, computer vision, and PLC integration, Everguard.ai helped the customer eliminate a critical safety risk around wrapper equipment. The solution enforces shutdown protocols automatically and prevents accidental machine activation—protecting workers in real time. This deployment not only enhanced on-site safety but also strengthened the company’s culture of proactive risk prevention.