US Steel Edgar Thomson Works Case Study

The challenge

High risk electrical maintenance and complex PPE requirements

United States Steel Corporation relies heavily on a sophisticated assortment of electrical equipment to drive and monitor the steel-making process. Consequently, ensuring the periodic maintenance of this equipment is crucial for the safety and productivity of its workforce. Over time, several challenges have emerged in guaranteeing the safe and consistent maintenance of the electrical equipment: complex PPE requirements, lack of visibility and PPE noncompliance, and lone workers. 

In late 2021, a significant incident occurred at the United States Steel (USS) UPI facility highlighted the pressing need to improve safety outcomes regarding electrical maintenance across all plants. Recognizing this urgency, USS forged a partnership in mid-2022 with WorkVis Inc. The WorkVis solution revolves around real-time video footage from
worksites, coupled with AI models that monitor and guide workers towards safe and productive outcomes.

The solution

AI-powered alerts on the job

To evaluate the feasibility of the WorkVis technology in addressing the challenges identified, a field trial was initiated at the Edgar Thomson Works in Braddock, PA, in mid 2022.

Through this collaboration with WorkVis, United States Steel aimed to address the challenges identified in electrical maintenance safety. By leveraging AI-powered video analysis, real-time alerts, and comprehensive analytics, USS sought to enhance worker safety, optimize productivity, and promote a culture of continuous improvement within its facilities. 

Strategically positioned cameras were installed in and around electrical maintenance areas of the plant to ensure comprehensive coverage of the work area, capturing real-time video footage of worker activities 24/7. Using this video data, the AI models were trained to identify various approved PPE, including the accurate detection of PPE presence or absence despite variations in age, cleanliness, and other differences. To ensure accuracy of the AI model, workers intentionally wore incorrect PPE that could potentially confuse the identification of correct PPE.

The AI model was further trained to recognize the initiation of work or the intent to work by workers, based on typical trigger actions such as opening electrical panel doors or specific body and arm orientations. Once work was identified to have begun, the WorkVis system automatically checked if the worker was wearing the appropriate PPE based on the type of equipment being handled. If unsuitable PPE was detected (as shown in Figure 1a), a voice alert immediately instructed the worker to halt work and guided them towards the correct PPE required for safe task execution. In the event that a worker persisted in working without suitable PPE, a notification was sent to a supervisor through a mobile app

The WorkVis mobile app also presented analytics to enhance visibility and provide teaching moments during safety talks and reviews. These analytics provided valuable insights for discussions on improving safety practices, allowing for a proactive approach to preventing incidents and enhancing overall worker safety.

The result

Better workplace safety, productivity and worker well being

The successful implementation of WorkVis has revolutionized workplace safety practices and significantly enhanced operational outcomes. By harnessing the power of real-time video monitoring and AI models, WorkVis has addressed critical challenges, leading to tangible and remarkable improvements across multiple plants.

Reduction in PPE Noncompliance: WorkVis' real-time monitoring capabilities have been instrumental in reducing instances of PPE noncompliance. By accurately detecting and ensuring the usage of appropriate personal protective equipment, the solution has effectively mitigated the risk of worker injuries and incidents. This US Steel facility experienced a 95% reduction in PPE noncompliance alerts from January 2024 to September 2024. A small percentage of this improvement can be attributed to other factors such as a PPE switch, seasonal variation, and model improvement. The implementation of WorkVis resulted in zero electrical PPE noncompliance incidents at Edgar Thomson Works, underscoring its impact on improving worker safety.

95% Reduction in PPE Noncompliance

Enhanced Incident Reporting and Analysis: WorkVis' advanced analytics and reporting features have provided invaluable insights into safety incidents and near misses. By capturing and analyzing data from video feeds, safety teams can conduct thorough investigations and identify underlying causes of incidents. This data-driven approach has facilitated proactive safety measure which resulted in zero electrical-related injuries where the AI technology was implemented, contributing to a safer work environment.

Lone Worker Safety: WorkVis has also addressed the safety concerns related to lone workers during electrical maintenance activities. By monitoring lone workers in real time and issuing proactive measures to warn of noncompliance the solution has dramatically improved lone worker safety.

In addition to these specific outcomes, the implementation of WorkVis has had broader positive impacts on US Steel Corporation's operations. The improved safety measures and streamlined workflows have resulted in a more motivated and confident workforce. Employees feel reassured that their well-being is prioritized, leading to increased job satisfaction and a stronger safety culture.

Furthermore, the integration of WorkVis has allowed for more effective resource allocation and planning. With real-time visibility into safety incidents and operational data, management can make data-driven decisions to optimize resource utilization, reduce costs, and improve overall operational performance. For instance, by identifying patterns of incidents, areas prone to higher risks can be targeted with additional safety measures, resulting in further risk reduction and operational stability.

The success of WorkVis has garnered attention not only within US Steel Corporation but also in the industry as a whole. The improvements in safety outcomes and operational efficiency have positioned US Steel Corporation as a leader in adopting cutting-edge technologies for workplace safety. The implementation of WorkVis has set an industry benchmark, highlighting the immense potential of AI-based solutions in creating safer and more productive work environments.

In conclusion, the implementation of WorkVis at US Steel Corporation has delivered significant results, transforming workplace safety practices and enhancing overall operational outcomes. The reduction in PPE noncompliance incidents, enhanced incident reporting and analysis, streamlined maintenance workflow, and improved lone worker safety are just a few examples of the positive changes observed.