In the demanding worlds of construction and manufacturing, ensuring the health and safety of the workforce has always been a critical priority. However, traditional approaches to health and safety management often fall short, relying on paper-based systems for risk assessments and manually delivered inductions requiring a high need for staff time and facilities to deliver training.
This system can be cumbersome, inefficient, and prone to errors. Static safety signage and generic training sessions often lack the engagement and context needed for true comprehension and retention. Furthermore, managing the safety of temporary visitors and contractors using manual processes can be particularly challenging, increasing the risk of incidents due to unfamiliarity with site-specific hazards.
Enter digital twins – virtual replicas of physical spaces and processes – powered by the world’s leading 3D capture platform Matterport. These dynamic, 3D captures of real world, data-rich environments offer a paradigm shift in how manufacturers can approach on-site health and safety. They capture the intricate details of a facility with millimeter-level accuracy, and include capabilities for creating completely customised health and safety experiences through interactive overlays, annotations, embedded documents, and even simulated scenarios.
Let’s delve into two key areas where this technology is making a significant impact
1. Comprehensive and Engaging Inductions
Traditional site inductions can often be time-consuming, overwhelming, and lack the immersive quality needed for true comprehension, often relying on non-interactive video or help sheets. Matterport digital twins offer a transformative solution.
● Pre-Arrival Familiarisation on Steroids: Imagine new employees or contractors being able to virtually “walk through” the entire facility before their first day. Using a Matterport digital twin, they can navigate production lines, locate emergency exits, identify first-aid stations, and understand designated walkways – all from the comfort of their home. This proactive familiarisation significantly reduces anxiety and improves their initial understanding of the site layout, potential hazards and what can be expected of them on day 1.
● Interactive Hazard Identification: Instead of static diagrams or lengthy presentations, safety managers can embed interactive elements directly into the digital twin. For instance, clicking on a piece of machinery could bring up information about its operational safety procedures, potential pinch points, or required Personal Protective Equipment (PPE). Similarly, confined spaces can be clearly marked with warning signs and links to relevant entry protocols.
● Customised Learning Paths: Different roles require different levels of safety awareness. With a Matterport digital twin, companies can create tailored induction experiences. A visitor might only need to understand basic emergency procedures and site access, while a new maintenance technician would require in-depth knowledge of specific equipment and isolation procedures. These customised paths ensure that individuals receive the information most relevant to their needs, improving retention and reducing information overload.
Example: A large automotive manufacturer could provide new assembly line workers with access to a digital twin of their specific work area weeks before they start. They could explore the location of emergency stop buttons, understand the flow of materials, and even virtually practice basic movements within their designated zone. Mandatory quizzes with pass/fail and individual submissions can ensure all inductions are completed ahead of arrival, saving both resources, staff time and the need to provide dedicated induction rooms on busy sites.
2. Enhanced Temporary Visitor Safety Management
Temporary visitors, such as contractors, auditors, or delivery personnel, often pose a unique safety challenge. They are unfamiliar with the site-specific hazards and protocols, increasing the risk of incidents. Matterport digital twins provide a powerful solution for managing their safety:
● Virtual Safety Briefings: Instead of time-consuming on-site safety briefings, visitors can be granted secure access to a specific area of the digital twin relevant to their visit. Embedded videos, documents, and interactive checklists can guide them through potential hazards, required PPE, and emergency procedures specific to their intended work zone.
Example: A construction company needing to bring in specialist welders for a short-term project can provide them with a digital twin of the specific welding area. Before arriving, the welders could review potential fire hazards, the location of fire extinguishers, designated welding sones, and any specific safety permits required. This pre-briefing ensures they arrive on-site already informed and prepared.
● Guided Virtual Tours: For complex or high-risk areas, companies can create guided virtual tours within the digital twin. A safety manager can remotely lead a visitor through the relevant sections, highlighting critical safety features and answering questions in real-time. This virtual guidance is entirely remote, removing the need for in-person escorts and ensures visitors are fully aware of their surroundings.
75% reduction in costly site visits
US-based construction firm, Knutson Construction Works reports in this Matterport case study
● Digital Permit-to-Work Integration: Matterport digital twins can be integrated with digital permit-to-work systems. Specific areas requiring permits can be clearly identified within the virtual tour. Visitors can be guided through the permit application process, ensuring all necessary safety checks are completed before work commences.
Why industry leaders are adopting digital twins to enhance health & safety
The adoption of Matterport digital twins for health and safety in manufacturing can result in significant benefits for companies:
● Reduced Incident Rates: By proactively identifying hazards, improving training effectiveness, and enhancing visitor safety, digital twins can contribute to a significant reduction in workplace accidents and near-misses. This directly translates to safer workers, reduced compensation claims, and fewer production disruptions.
● Cost Savings: Preventing accidents and streamlining safety processes also leads to substantial cost savings: lower insurance costs, fewer staff hours required to deliver inductions, less printed paperwork and administration. Furthermore, virtual training and remote site familiarisation can significantly cut down on travel and personnel costs associated with traditional methods.
● Improved Compliance: The detailed documentation and audit trails automatically generated through the use of digital twins simplify compliance with safety regulations. Real-time data and visual evidence demonstrate a company’s commitment to worker well-being, fostering stronger relationships with regulatory bodies.
● Enhanced Efficiency and Productivity: A safer workforce is a more productive workforce. When employees feel safe and well-trained, they are more confident and efficient in their tasks. Furthermore, streamlined contractor management and reduced downtime due to safety incidents contribute to overall operational efficiency.
● Stronger Safety Culture: By providing transparent access to safety information, facilitating collaborative problem-solving around safety concerns within the digital twin, and empowering employees with immersive training, companies foster a stronger safety-conscious culture throughout the organisation. This proactive approach to safety becomes ingrained in the company’s DNA.
Why changing your approach to health and safety is the safest option
Matterport digital twins are not just a futuristic novelty; they are a powerful and practical tool that is revolutionising health and safety in manufacturing and construction. By offering immersive, interactive, and customisable experiences for inductions, visitor management, and staff training, they empower companies to create safer, more efficient, and more compliant workplaces. As technology continues to advance, the adoption of digital twins will likely become a cornerstone of best-practice safety management in the manufacturing sector, providing a significant competitive edge for those who embrace its transformative potential.
VisualEyes has over 10 years experience delivering digital twin solutions for our clients. With the massive changes that the latest technomlogies are allowing in these sectors, we are happy to help guide you through the potential solutions and impacts digital twins could have on your business.
