I. Workplace Accident Statistics: Accidents Are Not Just a Problem with Equipment

In many studies on workplace safety, especially Heinrich’s Law, approximately 80–88% of accidents are attributed to unsafe human behavior. In many cases, equipment is functioning normally but is used incorrectly, and it is these small, repeated daily actions that become the main cause of serious incidents.

1. Common Causes of Accidents in Factories

Actions such as not wearing full PPE, ignoring safety procedures, entering hazardous areas, or rushing to save time are quite common in factories. The problem is that these actions are repeated daily but are very difficult to detect in time, leading to a constant risk of accidents.

II. What is Unsafe Behavior?

Unsafe behavior refers to human actions that can cause accidents or increase risks in the workplace.

Some common unsafe behaviors in factories include: not wearing a helmet or gloves, standing too close to operating machinery, entering restricted areas, climbing improperly, or bypassing interlocks to speed up operations.

The danger of these behaviors is that they often happen very quickly, are difficult to control, depend heavily on individual awareness, and can easily become “bad habits” if repeated over a long period.

III. Why is safety training still not enough?

Most factories have implemented comprehensive measures such as regular safety training, established clear operating procedures, and installed warning signs. However, accidents still occur in reality. And the main causes include:

Lack of 100% compliance: After a while, employees easily become “familiar with the job” and disregard procedures.
Production pressure: In an environment with KPIs and deadlines, speed is often prioritized over safety.

Training without monitoring real-world behavior: Training only provides knowledge, but does not guarantee real-world behavior.

You can conduct training multiple times, but just one instance of non-compliance is enough to cause an accident.

IV. What is a Blind Spot in Safety Monitoring?

Many factories still rely on traditional cameras, supervisory personnel, and post-incident reports. However, this approach has many “blind spots”: it cannot cover the entire area, does not detect risks in real time, does not guarantee continuous 24/7 monitoring, and lacks behavioral data for analysis.

In reality, traditional cameras only record events and support playback after an accident has occurred, but cannot provide immediate warnings or prevent risks early on.

V. AI-Based Behavioral Analysis Solutions

AI-based behavioral analysis (AI Safety Monitoring) helps businesses shift from a passive (reactive) monitoring approach to a proactive (proactive) approach.

AI-integrated camera systems can detect hazardous behavior in real time, identify PPE violations, provide immediate warnings via lights, sirens, or dashboards, and monitor continuously 24/7. Furthermore, all data is stored for systematic analysis and safety improvement.

The core difference lies in the fact that traditional cameras only record what has happened in the past, while AI can understand behavior and respond immediately.

VI. Learn about AI Safety Monitoring solutions for your factory

Workplace accidents are not random. In most cases, the cause stems from human behavior.

If relying solely on training, procedures, and manual monitoring, businesses remain reactive to risks. To truly improve safety, a system capable of seeing, understanding, and warning as soon as a risk arises is needed.

Learn how AI detects hazardous behavior in factories.

i-Soft Joint Stock Company – specializing in providing factory digitalization software solutions

►Address: 115 N2 Road, Long Truong Ward, Ho Chi Minh City, Vietnam
►Hotline: 0989 739 488
►Email: info@i-soft.com.vn