Process Integrated Computer Vision for Real-Time Failure Prediction in Steel Rolling Mill

We present a long-term deployment study of a machine vision-based anomaly detection system for failure prediction in a steel rolling mill. The system integrates industrial cameras to monitor equipment operation, alignment, and hot bar motion in real time along the process line. Live video streams are processed on a centralized video server using deep learning models, enabling early prediction of equipment failures and process interruptions, thereby reducing unplanned breakdown costs. Server-based inference minimizes the computational load on industrial process control systems (PLCs), supporting scalable deployment across production lines with minimal additional resources. By jointly analyzing sensor data from data acquisition systems and visual inputs, the system identifies the location and probable root causes of failures, providing actionable insights for proactive maintenance. This integrated approach enhances operational reliability, productivity, and profitability in industrial manufacturing environments.

Action Recognition based Industrial Safety Violation Detection

Proper use of personal protective equipment (PPE) can save the lives of industry workers and it is a widely used application of computer vision in the large manufacturing industries. However, most of the applications deployed generate a lot of false alarms (violations) because they tend to generalize the requirements of PPE across the industry and tasks. The key to resolving this issue is to understand the action being performed by the worker and customize the inference for the specific PPE requirements of that action. In this paper, we propose a system that employs activity recognition models to first understand the action being performed and then use object detection techniques to check for violations. This leads to a 23% improvement in the F1-score compared to the PPE-based approach on our test dataset of 109 videos.