The Road That Came With Proof
Vision AI · Safety · Driver Monitoring · Geofence · Maintenance · Zero Harm
Every site watched.
Every hazard stopped before it strikes.
Cognecto's Vision AI converts CCTV into an active safety layer—detecting PPE violations, zone intrusions, fire, fatigue, and geofence breaches in real time. No new hardware or manual rounds. Every event is timestamped, geo-tagged, and stored to support your Zero Harm mission.
Module 01
PPE Compliance
Helmet · vest · boots · face shield — all shifts
Module 02
No-Go Zone & Intrusion
Blast areas · dump edges · high-voltage corridors
Module 03
Fire & Smoke Detection
Fuel yards · coal stockpiles · workshops
Module 04
Driver Monitoring
Fatigue · distraction · overspeed · DMS
Module 05
Geofence & GPS Alerts
Route deviation · boundary breach · ANPR
Module 06
Equipment Monitoring
Working · idling · stopped · cycle analytics
Module 07
Predictive Maintenance
Sensor-based alerts · job cards · inventory
Module 08
Command Dashboard
Central control · scorecards · audit trail
Accident near-miss reduction
50%
50% reduction in near-misses across mining and EPC sites using real-time PPE and zone alerts to stop incidents before they escalate.
Faster emergency response
80%
80% faster incident response compared to manual rounds. Instant alerts hit mobile, WhatsApp, and the control room in under 150ms.
Digital evidence & transparency
100%
Every event is captured as geo-tagged, court-admissible video. No disputed incidents or missing records. Zero Harm on the record.
Module 01 + 02PPE Compliance Monitoring & No-Go Zone Intrusion Detection
Every worker checked.
Every restricted zone enforced.
PPE violations and no-go zone intrusions are top causes of industrial fatalities—and often missed by manual checks. Photon watches every camera, every second.
AI instantly detects missing helmets, vests, and boots across all zones without a human observer. No-go boundaries are drawn directly on feeds for blast areas, dump edges, and high-voltage zones. If breached, an instant alert delivers video evidence, time, and location straight to supervisors.
Helmet · high-vis vest · face shield · safety boots — all detected simultaneously
Access point enforcement — compliance checked before entry is permitted
Workforce accountability — automated shift-wise PPE compliance scorecards
Blast areas · dump edges · crane radii · excavations — all geo-fenced via camera
Video evidence attached to every alert — available for RCA and DGMS audit
25% improvement in PPE compliance · 50% reduction in intrusion violations
25%
Improvement in PPE compliance across all shifts
50%
Reduction in intrusion violations in hazardous zones
40%
Faster response time to critical safety conditions
4×
Operational efficiency — UPRRDA evidence-based monitoring
Module 03Fire, Smoke & Poor Visibility Detection
Fire detected at the spark.
Not after the explosion.
Standard sensors trip 10–20 minutes after ignition—often too late. Cognecto's Vision AI catches flame signatures and smoke trails early across your entire camera network.
Poor visibility detection acts as a second safety layer. By measuring camera brightness and blur, it triggers automated alerts during dust storms, fog, or low-light drops. Haul operators stop before collisions happen, ensuring safe movement when manual monitoring fails.
Early flame and smoke detection — fuel yards, workshops, coal stockpiles, conveyor belts
Automatic emergency notification — control room, WhatsApp, mobile app within 150ms
Recorded event evidence — video clip + timestamp + location for RCA and insurance
Visibility metrics — brightness, contrast, saturation, blur measured per camera continuously
Haul road caution alerts — fog, dust storm, low light trigger operational pause decision
Module 04Driver Monitoring System — Fatigue, Distraction & ANPR Access Control
The most dangerous machine
is a tired driver.
Fatigued operators driving 85-tonne haul trucks present massive risks. Geofences can't stop a 2 AM fatigue accident. A driver monitoring system does.
Our AI-enabled DMS uses in-cab cameras to spot eye closures and distractions, instantly triggering a buzzer and alerting the control room. Paired with GPS overspeed and route checks, it secures the biggest variable in site safety: operator behavior.
Fatigue detection — eye closure, head nod, microsleep patterns via in-cab AI camera
Distraction monitoring — phone use, face turned away, attention lapses flagged
Overspeed alerts — GPS-verified against haul road speed limits per segment
Vision-based haul path analysis — risky slopes, slippery zones, bottlenecks identified
ANPR access control — license plate recognition logs equipment entry/exit, flags unauthorised fleet
Dual evidence — in-cab video + telematics fusion for incident investigation
Module 05 + 06Geofence monitoring & equipment
Request a demo →
Geofence monitoring & equipment
working / idling intelligence.
Module 05 · Geofence
GPS Geofence & Route Compliance
Assets are tracked against configurable geofences for perimeters and haul routes. Route deviations or breaches fire instant control room alerts, while historical playback reconstructs paths for investigation.
Perimeter breach — site boundary crossed by unauthorised asset
Haul route deviation — tipper leaving assigned corridor
Parking zone violations — assets outside designated areas during shift
After-hours movement — any asset active outside scheduled shift windows
Route playback — full historical path reconstruction per asset per shift
Module 06 · Equipment
Equipment Working / Idling Monitoring
Vision AI classifies HEMM assets as working, idling, or stopped by tracking machine motion and hauling cycles. Idle time is flagged per shift, driving intervention and contractor accountability.
Working vs idling vs stopped — classified continuously per asset
Idle cost calculator — fuel burn during idle flagged as recoverable waste
Contractor billing transparency — verified working hours vs claimed hours
18–22% improvement in operational availability from idle reduction
Module 07 + 08Predictive Maintenance, Intelligent Alert System & Command Dashboard
All alerts. All assets.
One command screen.
Raw safety events—PPE violations, fire alerts, idle flags—can become noise without a unified command layer. Cortex's Alert Management Centre turns them into actionable intelligence.
The Dashboard consolidates video feeds, alerts, and heatmaps into one view, segmented by zone or contractor. Alerts are prioritized, routed, and tracked to resolution. ESG and DGMS compliance docs are auto-generated, while trend analytics expose root causes for audit teams.
Real-time monitoring — people, vehicles, and zone activity across every camera
Site/contractor/shift safety scorecards — ranked for transparent performance evaluation
Event recording with playback — video evidence for investigation and audit
Trend analytics — root-cause analysis across shifts, zones, and contractors
ESG & DGMS compliance documentation — generated automatically from alert log
Open API — push events and alerts to existing SCADA, ERP, or safety platforms
Alert Management Centre · Live · All Sites
13:15:49
PPE Violation — No safety vest
C-V33GN 3 · Zone B Entry · Camera 07
CRITICAL
13:11:22
Intrusion — Unauthorised personnel
C-V33GN 1 · Blast area perimeter · human body detected
CRITICAL
12:58:04
Driver fatigue alert — Eye closure sequence
DT-58 · Haul road segment 4 · Operator: Jacques
WARNING
12:44:33
Equipment idle — 22 mins over threshold
EX-189 · Bench 3 · Idle cost: 4.2L fuel est.
WARNING
12:31:17
Smoke detected — Remote fuel storage
C-V33GN 2 · Fuel yard north · early signature
WARNING
12:18:05
Maintenance scheduled — DT-56 cleared
2000-hour service completed · Next: 44,450 hrs
RESOLVED
All alert types covered
PPE violation
Zone intrusion
Fire & smoke
Driver fatigue
Overspeed
Geofence breach
Equipment idle
Poor visibility
Maintenance due
ANPR breach
Delivery: Control Room · Mobile App · WhatsApp · SMS · Email · API push
Module 07Predictive Maintenance · Sensor-Based Fault Detection · Job Cards · Inventory
7–15 Day Advance Alerts
Sensor-based fault detection on engines, hydraulics, and brakes sends service reminders 7–15 days before failure threshold — time to procure consumables without emergency procurement. 50–70% time saved on pre-start checklist execution with digital forms.
Digital Job Cards & History
Complete repair traceability — every job card linked to the asset, the fault code, the parts used, and the technician. SAP PM compatible. 250-hour, 2000-hour, and 5000-hour service schedules tracked against actual hour readings, not calendar dates.
Inventory & Stock Control
Stock-linked barcoded part issuance with low-stock alerts before job cards raise emergency orders. 25–30% fewer emergency procurements. Inventory connected to maintenance schedule — required consumables shown before the service is due, not when the machine is already stopped.
Industries
Built for every site where
Built for every site where
heavy equipment and people share space.
Open-Cast Mining
Coal, Lignite, Bauxite & Metal Mines
PPE at pit access points, blast area no-go enforcement, haul road driver fatigue monitoring, HEMM idle detection, fire detection at fuel and explosive storage, DGMS pre-start checklists. WCL, NLC, Hindalco, FG Gold, Canyon Resources — all active.
Plants & Manufacturing
Aluminium, Steel & Heavy Industry
24/7 PPE compliance across all three shifts — third-shift safety gap eliminated. No-go zone enforcement around hot metal zones, conveyor corridors, and overhead crane paths. BEML, Hindalco, thyssenkrupp, Vedanta — active deployments.
EPC & Construction
Highway, Infrastructure & Building Projects
Compaction progress visual recording, PPE compliance at all site entry points, no-go zones around excavations and crane radii, geofenced equipment compliance per BOQ package. UPRRDA, BRO, Camalco — evidence-based quality monitoring at scale.
Energy & Utilities
Power Plants, Substations & Fuel Facilities
No-go zone enforcement around high-voltage equipment, fire and smoke detection at fuel storage, PPE compliance for maintenance crews, ANPR access control at facility gates. Applicable to thermal, solar, and gas facility operations.
Logistics & Ports
Container Yards, Warehouses & Fleet Depots
Equipment idling and working detection in container yards, ANPR-based gate access control, geofenced movement compliance for yard vehicles, fire detection in warehouse storage areas. Real-time operational awareness across large, complex yard environments.
Defence & Government
BRO, Ordnance, Public Infrastructure
High-altitude construction safety monitoring for BRO, no-go zone enforcement at strategic infrastructure projects, equipment compliance and PPE monitoring across contractor workforces in remote and sensitive locations.
In the field. On the record.
Safety intelligence deployed
Safety intelligence deployed
across mines, plants, and infrastructure sites.
50%
Near-miss reduction
3
Breaches in 48hrs
24/7
Safety watch
"Bauxite and gemstone mining involves heavy excavators, haul trucks, and on-foot workers in close proximity every shift across three continents. Photon monitors every crane swing radius and geofenced hazard zone across all our operations simultaneously. We identified three no-go zone breaches in the first 48 hours — events that would never have been caught under the previous manual regime. Our safety directors in Mozambique, Madagascar, and Australia all see the same command dashboard. That cross-continental visibility is what Zero Harm requires."
50%
Near-miss reduction
3 continents
One command dashboard
Zero Harm
Programme standard
Fura Gems · Bauxite & Gemstone Mining · Mozambique, Madagascar, Australia
BEML Limited · Heavy Mining Equipment Manufacturing · India
UPRRDA · NH Corridor Package 6152 · Uttar Pradesh, India
Why CognectoWhy industrial operators choose Cognecto
Why industrial operators choose Cognecto
for EHS and equipment monitoring.
Not a generic CCTV analytics platform. Not a safety software tool. A purpose-built industrial intelligence layer trained on the specific visual signatures of mining, construction, and heavy industry operations — across 20+ sites on three continents.
01 / No Hardware Replacement
Works with your existing CCTV infrastructure.
Photon integrates with existing IP cameras via RTSP, RTMP, and ONVIF — Hikvision, Dahua, Axis, Bosch, and generic IP systems. The edge gateway plugs into your local network switch. No re-cabling, no new camera procurement, no civil works. The cameras you already paid for become active safety guardians. Deployment in 7 days.
02 / Industrial-Grade AI Models
Trained on dust, rain, and low-light worksites.
Generic Vision AI fails on dark, dusty, chaotic mine environments. Photon's models are pre-trained on thousands of hours of open-cast mining, construction site, and heavy plant footage — in the specific conditions where safety events occur. Near-zero false alarms means alerts are acted on, not ignored.
03 / IoT + Vision Together
Telematics and cameras from the same platform.
Boson's GPS and sensor telematics and Photon's Vision AI feed the same Cortex knowledge graph. A driver fatigue event from the DMS and an overspeed event from the GPS are correlated against the same haul cycle record. Incident investigation uses both streams simultaneously. One platform, not two.
04 / Court-Admissible Evidence
Not safety alerts. Safety evidence.
Every event detected by Cognecto is stored as a timestamped, geo-tagged, cryptographically signed record in Cortex — with the video clip attached. ESG reporting, DGMS audit documentation, contractor performance evaluation, and insurance claims all pull from the same verified event log. 85% of digital evidence and transparency improvements reported across active deployments.
Common questions
Everything you need to
Everything you need to
evaluate for your site.
Questions specific to your operation type — mine, plant, EPC, or infrastructure? Our team responds within 2 hours.
Request a demoDoes Cognecto require new cameras or can it use our existing CCTV?
Existing CCTV infrastructure is fully supported. Photon integrates with IP cameras via RTSP, RTMP, and ONVIF protocols — covering Hikvision, Dahua, Axis, Bosch, Mobotix, and generic IP systems. An edge gateway is installed on-site and connected to your existing camera network switch. No re-cabling, no hardware replacement, no civil works. For sites without adequate camera coverage, Cognecto can supply and install additional units as part of the deployment scope.
How does the Driver Monitoring System (DMS) work in mining vehicles?
A compact AI camera is mounted in the cab of the HEMM unit — typically on the dashboard facing the operator. The DMS runs AI models locally on the camera unit, detecting eye closure sequences (microsleep patterns), head nodding, phone usage, and face-away distraction events in real time. When a fatigue or distraction event is detected, an in-cab buzzer fires immediately for the operator and a simultaneous alert reaches the control room with the driver identity, asset, location, and a video clip. GPS overspeed data is fused with the DMS data for complete driver risk profiling per shift.
Can no-go zones be updated or reconfigured as the mine plan changes?
Yes. No-go zone boundaries are drawn on the camera feed interface and can be updated by authorised safety personnel without any technical support. As blasting areas shift, dump edges move, or new hazardous zones are created during mine plan progression, the geofence can be redrawn in minutes. The system supports multiple simultaneous zones per camera, each with its own alert priority and notification routing.
How does equipment working/idling detection work without manual tagging?
Vision AI analyses the camera feed for machine motion signatures — bucket and boom movement, chassis vibration, operator presence in the cab, and haul cycle proximity events. These visual signals are fused with Boson telematics data (engine state, GPS movement, ignition status) to classify each asset as actively working, idling under power, or completely stopped. The classification runs continuously and is logged per minute per asset — producing an idle time report per shift that is more granular and accurate than GPS alone.
How are ESG and DGMS compliance reports generated?
Cortex automatically generates compliance reports from the event log — no manual compilation required. DGMS pre-start checklist completion rates, PPE compliance percentages by shift and contractor, no-go zone violation counts, and maintenance schedule adherence are all calculated from verified event data. Reports are exportable in PDF and Excel formats, with the underlying event records (including video clips) available for any level of audit scrutiny. ESG reporting metrics — safety incident rates, near-miss frequencies, contractor safety scores — are available in the same system.
8 modules. Existing cameras. Active in 7 days.
Your site already has cameras.
Your site already has cameras.
Cognecto makes them
the safety layer you need.
Connect existing CCTV infrastructure to the edge gateway. Configure PPE zones, no-go boundaries, and alert routing. Deploy driver monitoring in HEMM cabs. Go live across all eight safety modules in 7 days. Every event evidence-ready from the first shift.
✓ Works with existing CCTV — no hardware replacement
✓ DGMS & ESG compliant — auto-generated audit records
✓ Active — Fura Gems · BEML · UPRRDA · Hindalco · WCL
✓ IoT + Vision AI — one platform, one evidence trail