AI Vision Safety Systems
MONOLITH Industrial Shield
Multi-sensor AI safety that sees, senses, and stops — before a worker becomes a statistic. Layered detection. Zero compromise.
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Multi-sensor AI safety that sees, senses, and stops — before a worker becomes a statistic. Layered detection. Zero compromise.
Four configurations, each adding a new layer of sensory certainty. From entry factory surveillance to full autonomous hazard intervention — every tier is a complete system, not a starter kit.
Each modality adds a new dimension of detection certainty. We don't do redundancy — we do complementarity.
Wide-area visual surveillance with AI object detection. Identifies people, PPE compliance, forklift paths, and zone intrusions at 400 sq ft per unit. The baseline — every other sensor adds certainty on top.
Best for: Well-lit production lines, loading bays, perimeter fencing
Detects human body heat (37°C) regardless of lighting, smoke, or fog. Impossible to fool with camouflage or clothing. Also flags overheating machinery before failure — a dual-purpose safety asset.
Best for: Cold stores, chemical plants, night shift, fire-risk zones
Millimetre-wave radar penetrates walls, racking, pallets, and visual obstructions. Fully privacy-compliant — no image, no identity, just presence. Operates in rain, steam, explosive vapour, and complete darkness.
Best for: Behind racking, GDPR zones, ATEX environments, outdoor
Precision 2D and 3D zone mapping with safety-rated output. Defines hard exclusion zones around robot cells with millimetre accuracy. Certified for safety-critical stop functions.
Best for: Robot cells, automated lines, entry/exit gate control
Bidirectional communication with your existing control systems. When the AI detects a hazard, it writes directly to the PLC to trigger an autonomous E-stop. SIL-validated. ISO 13849 PLd/PLe certified. The difference between an alert and a prevention.
Best for: Any facility where alert speed < human reaction time
Multi-gas sensors monitor LEL and toxic gas concentrations in real time. Vibration sensors flag machine-health deterioration before failure — all feeding the same unified safety platform.
Best for: Chemical plants, ATEX zones, predictive maintenance
| Scenario | Fixed Cam | PTZ Cam | Thermal | mmWave | LiDAR | Gas Sensor | PLC Stop |
|---|---|---|---|---|---|---|---|
| Person in danger zone | ✓ | ✓ | ✓ | ✓ | ✓ | ✗ | ✓ |
| Smoke / low visibility | ✗ | ✗ | ✓ | ✓ | ✗ | ✓ | ✓ |
| Person behind racking | ✗ | ✗ | ✗ | ✓ | ✗ | ✗ | ✗ |
| Night / no lights | ✗ | ✗ | ✓ | ✓ | ✓ | ✗ | ✓ |
| GDPR / privacy zone | ✗ | ✗ | ✗ | ✓ | ✓ | ✗ | ✓ |
| Gas / explosive atmosphere | ✓ | ✓ | ✓ | ✓ | ✗ | ✓ | ✗ |
| Robot cell intrusion | ✓ | ✗ | ✗ | ✗ | ✓ | ✗ | ✓ |
| Worker collapsed (man-down) | ✓ | ✓ | ✓ | ✗ | ✓ | ✗ | ✓ |
Light curtains, floor-mounted laser scanners and IR beams detect a single crossing of a single plane — once. They cannot tell whether a person is still inside. Monolith watches the entire volume, continuously, in 3D.
A light curtain registers a person crossing the beam — then forgets them. If the worker is still inside the cell when a colleague presses RESET and START, the palletizer runs. People die this way. Monolith continuously tracks every person inside the zone and inhibits the start while anyone remains — presence-aware, not just crossing-aware.
Pilz radar, SICK IR scanners and light curtains sit at knee-to-waist height on the floor line — directly in the path of forklifts, pallets and impacts. Our sensors mount overhead: nothing to clip, kick, mis-align or smash. Fewer nuisance faults, far longer service life, no realignment call-outs.
LiDAR turns the whole 25×25 ft arena into a live 3D cube; thermal, depth, stereo and mmWave add heat, distance and material certainty. A curtain guards one slice of air at one height. We guard the entire space — floor to ceiling — and re-zone it in software, with no rewiring.
Blind sensors halt the line for anything that breaks the beam — a box, a forklift, a swinging pallet. Monolith classifies what it sees, so it stops for a human and ignores product. Fewer nuisance stops means operators stop bypassing the guarding — the single most common root cause of guarding-related fatalities.
A cell has only a handful of gates. Monolith counts every person in and out, so it always knows the live occupancy of the zone — and inhibits restart until occupancy is provably zero. This solves the "whole-body access" gap (ISO 13855) that light curtains physically cannot: a worker who steps through and stands inside is still counted as present, even if no interior sensor can see them.
When a worker is occluded under the robot and the camera drops the track, thermal still sees body heat, LiDAR still sees the 3D mass, and overhead angles cover each other's blind spots. The governing rule is fail-safe: losing a track is never read as "the zone is clear" — the danger state holds until clearance is positively confirmed.
Pose AI recognises a collapsed or motionless posture — a worker fallen, unconscious, or trapped — and raises an immediate man-down alert, even on an unmanned night shift. A light curtain cannot tell standing from fallen. This one cannot only stop a hazard; it can save someone after one.
A PLC stores numbers; it cannot reason about them. Monolith reads your PLC and camera streams in real time and turns them into insight, foresight and evidence.
A pallet falls off the robot arm at 2am. Instead of scrubbing eight hours of footage, the plant head gets an instant alert and a ready-made clip — the anomaly timestamp ±1 minute of video. The event finds you.
Every detection and anomaly drops a clickable flag onto the video timeline. Click a flag, jump straight to the moment. Reviewing a shift takes minutes, not hours.
Our tracker predicts each person's trajectory ~1 second into the future. The system can stop the hazard before the worker reaches it — pre-emptive intervention, not just reaction. A reflex, not an alarm.
Cumulative heatmaps reveal where people actually move across the zone. Pinpoint high-traffic crossings, design safer walk-routes, and place guarding where the real risk is — backed by data, not guesswork.
We read PLC tags and logs in real time and surface analytics, correlations, root-cause and predictions the controller can't produce on its own — stop causes, alarm patterns, downtime drivers, all explained in plain language.
LiDAR reconstructs the full work cell as a live 3D volume — true height-aware safety zones, not a flat footprint. Define exclusion volumes in software and reshape them without touching a single cable.
High-quality Sony IMX678 sensors replace grainy legacy CCTV, fused with thermal, stereo, depth and mmWave. Sharper images mean more reliable AI — fewer misses, fewer false stops, usable evidence footage.
The plant head sees live detections, analytics, heatmaps and event logs from any browser — on-site or off. Full visibility of every protected cell, without standing on the floor.
Blind sensors halt the line for anything that breaks the plane — and every one of those needless stops is lost production. Because Monolith knows a person from a product, the machine stops only when a life is genuinely at risk. We measured the difference on a live palletizing line.
Figures from continuous PLC + vision logging on a real line; they scale with your line speed, shift pattern and product value. A live dashboard reports avoidable minutes and rupees recovered, updated every shift — so the safety system also reads as a productivity investment to your finance team, not just a cost.
A certified stop function is the floor, not the ceiling. The same sensors that protect your people quietly de-risk your balance sheet, your insurance, and your uptime.
Every zone entry that didn't end in contact is logged as a near-miss. You get leading safety indicators — the warning signs before an accident — instead of counting injuries after. Exactly the proactive data HSE auditors and insurers reward.
Every stop and incident is captured as timestamped, multi-sensor video. When something goes wrong, you have objective proof of exactly what happened and that the guarding performed — protecting the company in investigations, claims and litigation.
A certified, documented, fully audit-trailed AI safety system is a lever in your employers' and public-liability renewal. Demonstrable risk reduction and incident evidence translate directly into premium negotiations.
Reshape protected areas, exclusion volumes and rules in software for a product changeover or line reconfiguration — in minutes. No recommissioning, no recabling, no scaffolding to move a curtain.
A single overhead multi-sensor head replaces a perimeter of curtains, scanners and beams around a cell. Less wiring, less commissioning, fewer things to mis-align or fail — lower total cost of ownership.
The system continuously checks its own sensors and signals the PLC if a camera is blinded, moved, obstructed or failed. A mis-aligned light curtain can fail silently; Monolith tells you the moment it can no longer see.
The thermal layer flags overheating motors and bearings; vision anomalies surface abnormal machine behaviour. The safety platform doubles as an early-warning system for unplanned breakdowns.
Because it recovers measurable uptime and throughput, the business case reaches the Operations and Finance owners — not just the safety manager. A safety purchase that also reads as a productivity investment.
An opt-in module distinguishes authorized vs unauthorized personnel for a cell, flags entry by untrained staff, and supports accountability for guard-bypass and unsafe-restart events. Consent-based and privacy-gated, with an anonymized mode — off by default.
Monolith is deployed across sectors where a missed detection isn't a metric — it's a fatality.
Robotic cell guarding, conveyor line monitoring, PPE compliance, cobot collaboration zones. MONOLITH PRIME handles high-speed 6-axis robots with autonomous E-stop.
Zone 0/1/2 ATEX-certified sensors throughout. Thermal cameras immune to chemical vapour. Gas sensor integration for LEL monitoring. Full SIL validation for safety-critical stop functions.
Wellhead Zone 0, process area Zone 2. ATEX hardware throughout. Thermal detection critical in flare zones and steam environments. mmWave sees through condensate and vapour curtains.
Zone 2 for flour and sugar dust under the ATEX Dust Directive. Cold-store thermal imaging down to –20°C. Hygienic housing options. Conveyor safety and loading dock monitoring.
Forklift-pedestrian collision prevention, AGV/AMR zone management, loading dock intrusion detection. PTZ auto-tracking follows vehicles across 200m outdoor yards. Night-shift ready.
Zone 1 underground, Zone 2 surface. Explosive atmosphere sensing throughout. Thermal critical for underground dark environments. LiDAR zone mapping for heavy machinery exclusion areas.
"A single CCTV system has eyes. Our full multi-sensor platform has eyes, ears, a nose, a sense of touch, and the ability to feel through walls. Each sensor isn't just an add-on — it's a new sense. And just like in nature, an organism with more senses survives better. Your safety system should be no different. With every additional sensor, the probability of missing a person in your danger zone drops by an order of magnitude. That's not marketing — that's Bayesian probability. And that's what stands between your workforce and a preventable fatality."
Every Monolith system is engineered to specific safety standards. These aren't checkbox certifications — they're the legal and technical backbone of your liability protection.
Chemical, pharmaceutical, oil & gas, and food processing clients require ATEX-certified sensors for explosive atmosphere zones. Most AI safety vendors don't offer this. We treat it as baseline.
Alerts are useful. Autonomous stops are lifesaving. Our PLC integration is SIL-validated with full SISTEMA documentation — giving you legal defensibility and insurance coverage for every stop event.
Your IT team is not trained for OT/PLC security boundaries. Our AMC includes dedicated operational technology engineers. A misconfiguration in a safety-critical PLC write path is a liability you can't afford.
Safety systems demand uptime. Our service agreements are backed by on-shore UK engineers with contractual response times. No offshore helpdesks. No 48-hour ticket queues for a system that protects lives.
Tell us about your facility. We'll identify the right sensor configuration, generate a full BOM, and walk you through compliance requirements — at no cost, no obligation.