AI-Powered EHS/ESG Platform and Digital Shopfloor Transformation
Designed an enterprise-wide Environment, Health & Safety (EHS) platform and Digital Shopfloor ecosystem for the world's largest Heavy Engineering company. The solution transformed safety, compliance, and operational productivity by digitizing critical workflows such as Permit to Work, Incident Management, Safety Concern Reporting, compliance dashboards, and ESG reporting. The platform unified plant workers, supervisors, EHS managers, and corporate leadership on a single intelligent system powered by analytics and predictive insights.
Client
Heavy Engineering Company
Duration
42 weeks
The Challenge
Safety and compliance processes were managed through paper forms, emails, and spreadsheets. Permit to Work approvals were slow, manual, and difficult to audit. Incident reporting lacked standardization and root-cause visibility. Safety concerns and near misses were often underreported. EHS teams had limited real-time visibility into compliance across plants. ESG reporting required extensive manual data consolidation. Shopfloor managers lacked integrated operational and safety insights. Leadership needed predictive analytics to proactively reduce risk.
Our Approach
Conducted discovery workshops with plant operations, EHS teams, and corporate sustainability stakeholders. Designed a unified Digital Shopfloor and EHS platform accessible via web and mobile applications. Implemented core modules including: Permit to Work (PTW) Automation Digital permit creation, approval, and closure Risk assessments and isolation checklists Multi-level approval workflows QR-based permit verification and audit trails Incident Management Mobile reporting of incidents, near misses, and unsafe acts Root cause analysis and corrective action tracking Escalation workflows and automated notifications Safety Concern Reporting System Easy reporting by frontline workers Anonymous submissions Resolution tracking and accountability EHS Compliance Dashboard Real-time KPIs for incidents, permits, inspections, audits, and corrective actions Plant-wise and enterprise-wide compliance views ESG Compliance and Sustainability Reporting Consolidated environmental, safety, and governance metrics Automated reporting for corporate sustainability disclosures Digital Shopfloor Analytics Operational and safety metrics integrated into a single executive dashboard Predictive analytics for incident trends and compliance risk
The Outcome
Digitized end-to-end EHS and safety workflows across all manufacturing sites. Improved reporting culture and frontline participation. Accelerated approvals and corrective action closures. Enabled real-time visibility into safety and compliance performance. Simplified ESG data consolidation and executive reporting. Created a scalable foundation for predictive safety and operational excellence.
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