Development and implementation of digital technical control systems to correct dangerous personnel behavior

From historical injury rates to predictive safety

The transformation of the HSE system at large industrial enterprises is impossible without a deep analysis of historical data and the implementation of objective control tools. In a workforce of thousands and complex production processes, traditional supervision methods often fail, leading to the concealment of micro-injuries and a formal attitude toward rules. In this webinar, Alexander Bondarenko, Head of HSE at SSGPO JSC, analyzes a practical case of transitioning from a reactive management model to a proactive one using digital technical control systems.

Using his enterprise as an example, the speaker shows how analyzing incident statistics over 65 years helped identify the top 5 critical risks. It turned out that the greatest threat was not frequent minor incidents, such as slips and trips, but work in electrical installations, interaction with railway and motor transport, blasting operations, and falls from height. It was in these areas that digital control was focused to prevent fatal injuries.

Drones, thermal imagers, and wearable DVRs

To ensure transparency and correct dangerous personnel behavior, the enterprise implemented a multi-level monitoring system. The use of unmanned aerial vehicles (UAVs) made it possible to supervise work operations from a significant distance. This solves two tasks at once: identifying hidden violations in hard-to-reach places and creating the effect of inevitable control, which disciplines workers.

In addition to visual monitoring, drones are equipped with thermal imagers to search for corona discharges on power lines, assess the wear of chimney linings, and perform thermal measurements of charged blocks. This allows identifying technical defects before they lead to an emergency situation.

To control high-risk work, the presentation details the use of wearable video recorders. Mandatory video recording of the issuance of work orders, briefings, and the work process itself (for example, in electrical installations) eliminates a formal approach and provides a reliable basis for subsequent analysis of the causes of dangerous behavior.

Surround view systems and public feedback

A large-scale network of more than 1,500 video control systems has been deployed on mining equipment and transport. The implementation of surround view and blind spot monitoring systems on excavators and bulldozers minimizes the risks of running over people and equipment. Additionally, driver fatigue monitoring systems are used, tracking distraction, smoking, or eating while driving.

The collected video content is used not only to record violations but also for continuous learning. The enterprise has equipped hundreds of screens in work order issuance rooms, where short videos analyzing real incidents are broadcast before the start of a shift. The public demonstration of mistakes, indicating causes and consequences, works as a powerful incentive to change the behavioral habits of the entire team.

What you will learn from this webinar:

• How to analyze historical injury statistics and identify truly critical risks?
• How does the use of UAVs help control hard-to-reach objects and identify hidden technical defects?
• How to implement mandatory video recording of work orders and high-risk work in production?
• Which digital tools are most effective for monitoring blind spots and driver fatigue in mining equipment?
• How to use CCTV footage to create educational content and transform the safety culture?