Stopping Conveyor Belt Ignition and Hydraulic Hotspots in an Automotive Pressing & Assembly Plant
Continuous mechanical vibration, stamping press friction, and oil mist previously caused conveyor fires and false alarms. By deploying FireVision onto 12 existing factory CCTV cameras, the plant caught a smouldering drive bearing in 4.2 seconds—saving £140,000 and preventing 36 hours of unscheduled line stoppage.
Mechanical Friction, Oil Mist & £18,000/Hour JIT Downtime
Heavy industrial stamping environments present extreme physical conditions that defeat traditional smoke detectors, creating dangerous unmonitored conveyor friction zones.
The Friction & Hydraulic Hazard
24/7 stamping presses, hydraulic lines, and long underground scrap transfer conveyors run continuously under high mechanical load. Bearing seizures and hydraulic line micro-leaks historically created dangerous flash-flame risks along the conveyor route.
Hostile Environmental Conditions
Heavy oil mist, metallic particulate dust, and ambient radiant heat from stamping machinery rendered conventional optical and ionization detectors useless, causing frequent sensor failure and unmanageable false alarms.
£18,000/Hour Downtime Penalties
In a tier-1 just-in-time automotive supply chain, unscheduled line shutdowns cost £18,000 per hour in OEM delivery penalties, making false alarm line halts as economically destructive as small fires.
Sub-5s Optical Intercept Across 12 Existing CCTV Cameras
Rather than installing expensive point sensors prone to oil mist fouling, FireVision integrated with the factory's existing CCTV network to deliver continuous visual friction scanning.
Targeted Machine Hazard Zones
Configured FireVision across 12 existing IP camera streams focused directly on high-wear bearing housings, hydraulic power packs, and the 80-metre scrap discharge conveyor line with zero production interruption.
Dynamic Time-Window Filtering
Activated hyper-sensitive smoke detection along conveyor beds while teaching the vision model to differentiate between scheduled steam releases, cutting fluid vapors, and genuine friction smoke.
Automated SCADA & Pager Integration
Linked FireVision webhook alert dispatches directly into the plant SCADA monitoring screen and maintenance supervisors' pagers with real-time video snapshots, ensuring immediate targeted response.
Measured Production Impact Over 6 Months of Continuous Stamping
Captured a live bearing seizure smoulder on the scrap conveyor before flames penetrated the press pit.
Prevented a 36-hour total factory shutdown, avoiding OEM late-delivery contractual penalties.
Completely filtered out cutting fluid vapors, hydraulic spray, and welding flash without false trips.
Utilized the plant's existing Axis and Hanwha factory CCTV cameras with zero new wiring or conduit.
“A conveyor fire in our sub-floor scrap run could easily take out our main press line for three days. FireVision caught an overheating drive roller smouldering on camera four minutes before any physical sensor in the building triggered. It kept the entire factory running.”
Eliminate Industrial Fire Risks on Your Critical Production Lines.
Identify machine hotspots and conveyor risks before they trigger a multi-day factory shutdown. Pilot on 5 production cameras in 15 minutes.