Case Study
Transforming Warehouse Safety at Scale in the USA
The Impact of Innovation
Following successful trials at Tyson Foods' Discovery Center, Bigmate partnered with the food processing giant to deploy the WARNY Warehouse Safety Solution across five major distribution centers. This enterprise-scale implementation aimed to enhance worker safety in high-risk environments where forklifts, personnel, and loading dock operations intersect daily.
- - Scale: 4 major distribution centers
- - Locations: Alabama, Kentucky, North Carolina, Virginia
- - Coverage: Approximately 40 cameras per site
- - Technology Used: Edge Computing, Computer Vision, AI
- - Implementation: 1-3 months per site
- - Key Use Cases: Person-forklift proximity, forklift-forklift interaction, trailer safety
- - Target Outcome: Real-time safety intervention and incident prevention
The Challenge
Enhancing Safety Across Multiple Facilities
In today's high-velocity food processing and distribution environments, Tyson Foods faced a critical safety challenge: protecting workers and equipment across multiple large-scale facilities where pedestrians and heavy machinery frequently interact. The traditional approach of relying solely on operator vigilance and administrative controls was insufficient for Tyson's commitment to workforce safety.
Challenges:
The Solution
WARNY Optical Intelligence Solution
Bigmate's WARNY system was implemented to provide comprehensive safety monitoring and alerts across Tyson's distribution centers. The solution focused on three critical use cases: person-forklift proximity detection, person-truck interaction monitoring, and trailer safety monitoring at loading docks. By processing all detection at the edge, WARNY delivers real-time alerts without relying on cloud connectivity.
Key Features of WARNY:
Overcoming
Implementation Challenges
The multi-site deployment presented several significant challenges that required innovative solutions. Ensuring AI consistency across diverse environments, integrating with existing infrastructure at scale, and developing customized safety rulesets for each facility required careful planning and execution.
Key Implementation Challenges:
Results
Enhanced Safety Across Facilities
The WARNY system is now fully operational across five Tyson Foods distribution centers, monitoring approximately 200 camera feeds and providing real-time safety protection. The system is actively detecting personnel within unsafe proximity of moving forklifts, monitoring person-to-forklift & truck-to-person interactions, and identifying when personnel are inside trailers at loading docks.
Key Operational Capabilities
The implementation has transformed safety management from a reactive to proactive approach by providing real-time awareness of safety violations, creating standardized safety data across multiple facilities, enabling safety teams to identify high-risk areas and operational patterns, and reducing reliance on administrative controls alone.
Conclusion
A Safer Future for Food Distribution
The WARNY implementation at Tyson Foods demonstrates the scalability and adaptability of edge-based computer vision safety systems across large enterprise deployments. By leveraging existing camera infrastructure while adding intelligent detection capabilities, Tyson has enhanced warehouse safety without disrupting operations.
This enterprise-scale deployment serves as a model for how innovative technology can be applied consistently across diverse facilities while maintaining high detection accuracy and operational reliability. The partnership between Bigmate and Tyson Foods continues with ongoing monitoring, system refinement, and exploration of additional safety use cases.
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