Mumbai, Aug. 28 -- Sujeet Kumar Singh, Founder, HSESkillEdge, discusses the evolution of a technology-enabled safety ecosystem, backed by visible leadership, which is changing the way cement manufacturers are perceiving safety norms.
Preventable incidents continue to occur in cement plants that have invested heavily in safety systems and PPE. Sujeet Kumar Singh, Founder of HSESkillEdge, lists down complacency, normalisation of deviations and a compliance mindset as part of the challenge. In this interview, he maps the full spectrum of digital safety technologies that are currently transforming risk management within cement plants.
How is the definition of safety in the cement industry evolving from regulatory compliance to a strategic driver of operational excellence?From an Occupational Health and Safety (OH&S) perspective, safety in the cement industry has transformed from a compliance-driven function focused on accident prevention into a strategic, risk-based management system that protects people while driving operational excellence and supporting 'Net Carbon Zero' goals.Modern cement plants are increasingly adopting artificial intelligence (AI), industrial internet of things (IIoT), virtual reality (VR), training simulators, geofencing, geotagging, GPS-enabled vehicle safety systems, wearable technologies, drones, robotics and predictive analytics to proactively identify hazards, monitor critical risks, and improve worker health and safety. AI-powered video analytics detect unsafe acts and PPE non-compliance in real time and generate audio alarm, while wearable devices monitor fatigue, heat stress and physiological parameters.Predictive maintenance minimises the risk of catastrophic equipment failures, and drones and robotic inspection systems eliminate the need for personnel to enter hazardous areas such as kilns, silos, preheaters and confined spaces. Advanced AI-based process optimisation enhances combustion efficiency, reduces dust and greenhouse gas emissions, improves energy efficiency and lowers workers' exposure to hazardous pollutants.By integrating digital technologies with strong safety leadership, occupational health management, and a proactive safety culture, the cement industry is creating safer, healthier and more sustainable workplaces that enhance operational reliability while accelerating the journey toward 'Zero Harm and Net Carbon Zero'.
With increasing automation and digitalisation, how can cement companies ensure that technology strengthens rather than replaces a strong safety culture?Increasing automation and digitalisation should strengthen, not replace, a strong safety culture. Technologies such as AI, IIoT, wearable devices, drones, and digital Permit-to-Work systems help identify hazards, predict failures, and reduce worker exposure to risks. However, sustainable safety performance depends on a top-down commitment through Visible Felt Leadership (VFL) and a bottom-up approach that actively engages employees in hazard identification, risk assessment, and continuous improvement.By integrating advanced technologies with strong leadership, workforce participation, competency development and human oversight, cement companies can build a resilient safety culture that supports Zero Harm, operational excellence, and Net Carbon Zero.
Which emerging technologies-from IoT and AI to digital permit-to-work systems-are creating the biggest impact on risk prevention in cement plants?Advanced digital technologies enable proactive hazard identification and predictive risk management, significantly reducing worker exposure to hazardous environments while improving compliance with Permit-to-Work (PTW), Lockout/Tagout (LOTO), and other critical risk controls. They provide early detection of equipment failures, fires, and occupational health hazards through continuous monitoring, while robotics, drones, and remote inspection systems make maintenance safer by minimising human intervention in high-risk areas.By reducing human error, enhancing emergency response, and improving asset reliability and operational efficiency, these technologies accelerate the cement industry's journey toward Zero Harm, Operational Excellence, Industry 4.0, and Net Carbon Zero.
Technology Key Safety BenefitsAI Computer Vision Detects PPE non-compliance, unsafe acts, restricted area access, housekeeping issues, and vehicle-pedestrian interactions in real time and generates audio alert.AI Thermal Imaging Identifies burner instability, electrical hotspots, overheated bearings, clinker cooler failures, and early fire risks before catastrophic failures occur.IIoT Smart Sensors Continuously monitor dust, toxic gases, oxygen, vibration, temperature, and structural health for early hazard detection and predictive maintenance.Confined Space Gas Telemetry Enables remote gas monitoring and lone-worker protection, reducing confined space entry risks.Preheater Cyclone Blockage Radiography & AI Analytics Detects and predicts cyclone blockages without opening equipment, minimising exposure to hazardous conditions.Robotics & Remote Inspection Robots, crawler systems, and drones perform inspections and maintenance in kilns, silos, stacks, roofs, and mines, eliminating work at height and confined space entry.Smart LOTO Digitally verifies energy isolation using RFID and electronic authorisation, preventing accidental energisation.Digital Permit-to-Work (PTW) Digitises permit approval, photo verification, gas testing, and SIMOPS control, improving compliance and reducing human error.Smart Wearables Monitor heat stress, fatigue, falls, and worker health, enabling rapid emergency response.GPS, Geofencing & AI Driver Monitoring Prevent over speeding, unsafe driving behaviour, and vehicle collisions in plants and mines.Clinker Cooler & Conveyor Machine Vision Detects damaged grate plates, hot clinker accumulation, belt misalignment, tears, and spillage for safer operations.AI Acoustic Monitoring & Predictive Analytics Predict equipment failures through sound pattern analysis and condition monitoring, preventing unexpected breakdowns.Digital Twin, AR & VR Improve safety through virtual training, remote maintenance assistance, and simulation of hazardous scenarios.Smart Fire Detection & Fiber Optic Heat Detection Provides early detection of fire, smoke, and overheating in coal mills, cable galleries, and conveyors.Integrated Command Center & AI Risk Analytics Offers centralised real-time safety monitoring, predictive risk assessment, faster incident reporting, and integrated ESG/OH&S performance dashboards.
Despite significant investments in safety systems and PPE, why do preventable incidents still occur, and what fundamental shift is needed?Despite significant investments in safety systems, PPE and digital technologies, preventable incidents continue to occur because most are driven by human factors, weak safety culture, and inconsistent implementation of critical risk controls rather than the absence of procedures or equipment. Common causes include complacency, normalisation of deviations, inadequate supervision, poor risk perception, ineffective communication, production pressure and failure to learn from near misses.The fundamental shift required is from compliance-based safety to a culture of ownership and operational discipline, where Visible Felt Leadership (top-down commitment) is combined with active workforce participation (bottom-up engagement). Safety should become a core organisational value, supported by predictive technologies, continuous learning and accountability, so that every employee proactively identifies, reports and controls risks, before they lead to incidents, enabling the journey toward Zero Harm.
How can cement companies build a safety culture where contractors, frontline workers and leadership share equal ownership of safety outcomes?Cement companies can build a shared safety culture by making safety a collective responsibility rather than a management function. This requires a top-down approach through Visible Felt Leadership (VFL), where leaders demonstrate commitment by regularly engaging with frontline teams, and a bottom-up approach that empowers employees and contractors to identify hazards, stop unsafe work, report near misses and participate in risk assessments.Contractors should be held to the same safety standards, competency requirements, and performance expectations as permanent employees through robust onboarding, digital contractor management, and continuous training.By fostering trust, open communication, recognition of safe behaviours, and accountability at every level, supported by digital tools such as AI, IIoT and digital PTW systems, cement companies can create a culture where everyone owns safety, every task is performed safely, and every incident is preventable, driving the journey toward Zero Harm.
As alternative fuels, waste co-processing and decarbonisation reshape cement manufacturing, what new safety challenges should the industry prepare for?As cement plants adopt alternative fuels, waste co-processing and decarbonisation technologies, they face new safety challenges, including fire and dust explosion risks, toxic and flammable gas exposure, biohazards, preheater blockages, hot material blowouts and process instability. Managing these evolving risks requires advanced engineering controls, AI, IIoT sensors, thermal imaging, smart gas monitoring, robotics and predictive analytics, supported by ATEX-compliant designs, automated fire protection, enhanced PPE, competency-based training and robust process safety management.
Emerging Challenge Key Risks Technology & Safety ControlsAlternative Fuels (AFR) and Waste Co-processing Fire, spontaneous combustion, dust explosions, unstable combustion, process upsets AI thermal imaging, explosion-proof (ATEX) design, automated fire suppression, deflagration venting, continuous temperature monitoringToxic Chemical and Biological Hazards Exposure to H2S, NH3, CH4, corrosive gases, pathogens, chemical splashes, oxygen deficiency Smart multi-gas wearables, forced ventilation, gas telemetry, biological PPE, chemical-resistant PPE, health surveillancePreheater Blockages and Hot Material Hazards Cyclone build-up, hot material blowback (>800degC), refractory failures, structural damage Remote hydro-robots, AI blockage prediction, radiography, thermal imaging, predictive monitoring, Smart LOTOEngineering and Operational Controls Explosion, fire, structural failures, unsafe maintenance ATEX-compliant equipment, negative-pressure ventilation, blast walls, explosion vents, infrared monitoring, automated suppression systemsAdvanced PPE and Competency Heat stress, burns, toxic exposure, biohazards Aluminised heat suits, chemical-resistant PPE, PAPR respirators, cut-resistant gloves, competency-based training and emergency preparedness
What will distinguish the safest cement plants of the future from those that simply meet compliance requirements?The safest cement plants of the future will move beyond reactive compliance to predictive, technology-enabled safety ecosystems that prevent incidents before they occur. Industry leaders will eliminate worker exposure to high-risk tasks through automation, robotics, drones, and AI, while using predictive analytics, AI-enabled vision systems, connected smart PPE, digital LOTO and real-time health and environmental monitoring to proactively manage risks.Safety will extend beyond the plant through contractor and logistics safety integration, ensuring the same high standards across the entire value chain. By combining advanced technologies with strong leadership and a proactive safety culture, future-ready cement plants will achieve Zero Harm, operational excellence and sustainable manufacturing.
Published by HT Digital Content Services with permission from Indian Cement Review.