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Module OS · Metalya Safety

Operational Safety

Computer vision that detects risk conditions to protect people, not to monitor them.

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Why it matters

Metalya Safety uses computer vision and AI to detect risk conditions, prevent incidents and protect people on production floors, in warehouses and in high-risk work areas. It analyses camera images, also from existing CCTV, and turns critical situations and near misses into alerts and actionable safety insights. It is built on a clear principle, protecting people, not monitoring: it focuses on the operational context and is not designed to control workers, measure productivity or evaluate individual performance.

  • Risks detected earlier

    Potentially dangerous conditions and near misses are recognised before they escalate into incidents.

  • Protection, not surveillance

    The focus is on risk conditions in the environment, not on individual performance.

  • Works with existing cameras

    Video from compatible CCTV cameras can be analysed, often without major hardware changes.

Key features

What it does

  • 01

    Fire and smoke detection

    Detects early signs of fire or smoke in operational areas, for faster awareness and response to potential emergencies.

  • 02

    Suspended load monitoring

    Detects people or vehicles standing or moving under suspended loads, around cranes, hoists, overhead handling systems and lifting operations.

  • 03

    Collision risk detection

    Detects people, vehicles or objects entering the operating area of moving machinery, robotic cells or mobile equipment such as forklifts.

  • 04

    PPE compliance

    Checks whether workers wear the required personal protective equipment, such as helmets, high-visibility clothing, gloves and safety glasses.

  • 05

    Man-down detection

    Detects a worker lying on the ground who may need immediate assistance, enabling a faster response.

  • 06

    Work area delimitation

    Verifies that work areas, maintenance zones and restricted spaces are properly marked, separating them from pedestrian routes.

  • 07

    Blocked routes and emergency exits

    Detects obstacles along transit routes, pedestrian paths and emergency exits, for safer circulation and faster evacuation.

  • 08

    Custom risk scenarios

    Configurable for site-specific conditions based on layout, procedures and rules, such as ID badge recognition in controlled zones or ladder and harness use when working at height.

From camera to human action

The system raises awareness. People decide.

Computer vision watches the operational context — vehicles, machinery, loads, routes, areas — and gives safety teams earlier awareness of risk conditions and near misses. People stay in charge of every decision.

  1. 01 · CameraBay 3 overhead camera
  2. 02 · Risk conditionPerson inside the crane exclusion zone during a lift
  3. 03 · AI detectionPerson and load path overlap detected
  4. 04 · Safety insightNear miss recorded with time, area and image
  5. 05 · Human actionSupervisor stops the lift; procedure reviewed

Illustrative scenarios. Detection thresholds, areas and notification rules are configured per site with the safety team.

Safety is an investment

A safer workplace protects people, reduces operational risk and strengthens the company. In industrial and logistics environments, investing in safety helps reduce incidents, unplanned downtime, indirect costs, disputes and lost productivity. It also improves the quality of work, builds employee trust and supports the company's reputation with customers, partners and institutions. Metalya Safety helps turn that investment into everyday prevention, because protecting people also means protecting the future of the business.

  • Detect risks and near misses earlier

    Recognise potentially dangerous conditions before they escalate into incidents.

  • Enable faster intervention

    Provide timely information to safety, operations and site teams when critical conditions are detected.

  • Reduce interference between people, vehicles and machinery

    Support safer coordination where workers, forklifts, vehicles and equipment operate in the same spaces.

  • Support a proactive safety culture

    Make prevention more visible, measurable and part of everyday operations.

Protecting people, not monitoring

The system looks at the operational context: unsafe areas, moving vehicles, machinery, suspended loads, blocked routes, missing delimitations, fire or smoke, man-down situations and other conditions that may affect people's safety. Turning field events into safety insights helps identify recurring critical conditions, strengthen procedures, improve training and build safer workplaces. The goal is to protect people, not to judge them. Metalya Safety supports the teams responsible for safety, prevention and operational continuity: it does not replace their responsibility, but strengthens their ability to observe, analyse and respond.

  • HSE managers

    Real-time insights to identify unsafe conditions, recurring risks and critical scenarios across operational areas.

  • Safety officers (RSPP)

    Support for prevention, risk analysis, procedure improvement and workplace safety management.

  • Plant managers

    Greater visibility over risk conditions in production areas, operational flows and zones where people and machinery interact.

  • Warehouse managers

    Support for safer forklift circulation, pedestrian routes, loading bays, storage areas and emergency paths.

  • Supervisors and team leaders

    Timely information to intervene faster during daily operations and encourage safer behaviour in the field.

  • Employers and management

    A more measurable, proactive and structured approach to workplace safety, with benefits for people, operations and business continuity.

From cameras to safety intelligence

Images from operational areas are turned into real-time safety information in three steps. The system detects people, vehicles, machinery, routes, work zones and potentially unsafe conditions, helping safety and operations teams recognise risks earlier and respond faster.

  • Image acquisition

    Cameras capture real-time images of production floors, warehouses, logistics areas and other operational environments.

  • AI analysis

    Computer vision algorithms analyse people, vehicles, machinery, routes, work zones and risk conditions in the scene.

  • Alerts and safety insights

    When a critical situation is detected, the system generates an alert and turns visual data into information for prevention and intervention.

From near miss to prevention

A near miss causes no injury, but it reveals a real risk condition. When such events repeat, they become important signals: they help identify recurring risks, strengthen safety procedures and improve the traceability of prevention actions. By detecting potentially dangerous conditions in real time and turning them into safety insights, Metalya Safety helps teams intervene earlier, analyse critical situations and take a more proactive approach to prevention. Every near miss detected is an opportunity to prevent an incident.

Built for dynamic, high-risk environments

Metalya Safety is designed for areas where people, vehicles, machinery and materials interact every day. Its computer vision capabilities can be adapted to different layouts, workflows and risk scenarios.

  • Production floors

    Risk conditions around machinery, production lines, robotic cells, temporary maintenance areas and moving equipment, to help teams identify unsafe situations earlier.

  • Warehouses and logistics areas

    Where forklifts, pallet trucks, pedestrians, loading bays, storage areas and transit routes interact: dangerous proximity, blocked routes, obstacles and access to restricted areas.

  • Industrial plants

    Unsafe access, missing PPE, blocked emergency routes, man-down situations and presence near moving machinery, in spaces shared by processes, equipment and people.

  • Construction and outdoor areas

    Heavy vehicles, suspended loads, temporary work zones and site conditions that change throughout the day, including infrastructure sites.

Detection features

Detection features cover four areas: people and PPE, moving equipment, operational spaces and critical events. Specific scenarios, such as ID badge recognition or work at height, can be added, and the system can be configured around each site's layout, procedures and operational rules.

  • People and PPE

    Unsafe conditions involving people, protective equipment and emergencies, such as man-down situations.

  • Moving equipment

    Dangerous interactions between workers, forklifts, vehicles and moving machinery.

  • Operational spaces

    Access, routes, obstacles and work area delimitations, to keep spaces clear and organised.

  • Critical events

    High-impact conditions, such as fire or smoke, that call for fast awareness and a timely response.

  • ID badge recognition

    Detects ID badges in operational areas, to help verify authorised presence in specific or controlled zones.

  • Ladder and safety harness monitoring

    Helps identify improper ladder use or missing fall protection where work at height is carried out.

Privacy, compliance and responsible AI

Technology should support prevention, not surveillance. Metalya Safety can be configured according to each company's safety policies, operational context and compliance requirements, and every deployment must follow company procedures and the applicable regulations.

  • Data protection (GDPR)

    Designed according to the principles of the GDPR (EU Regulation 2016/679): images are analysed to identify risk situations, not to monitor individual workers. Measures may include data minimisation, privacy by design and by default, controlled access and, where appropriate, anonymisation or pseudonymisation.

  • AI Act principles

    Developed following the principles of the European Artificial Intelligence Act: transparency in the use of AI, risk management and mitigation, and human oversight of operational decisions.

  • Safety documents

    Designed to work alongside the documents required by Italian workplace safety regulations: DVR (risk assessment), DUVRI (interference risk assessment), PSC (safety and coordination plan) and POS (operational safety plan). It does not replace them, but can help verify that operations take place under the expected safety conditions.

  • Assessed site by site

    Every deployment is assessed with the customer's safety officer, data protection officer and employee representatives, against applicable data protection, workplace and AI regulations. Compliance depends on how the system is configured and used at each site.

  • Existing CCTV

    Video streams from compatible security cameras can be analysed, so current systems can be used without major hardware changes, for faster deployment and less disruption.

In the platform

One of the modules of Metalya Core. Every module shares one governed data model, so what happens here is immediately visible to planning, quality, materials and maintenance — and Metalya Studio adapts it to the way your plant works, with AI.

Works together with

Buy the foundation. Adapt the experience.

See Metalya on your own production scenario: your routings, your constraints, the screens your people need.

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