How a Global Chemical Manufacturer Scaled Operational Intelligence with Protex AI
Bringing visibility and efficiency to high-risk manufacturing operations.
Limited Visibility in Complex, High-Risk Environments
This global specialty chemicals leader operates across hazardous environments with strict safety standards. Despite a mature safety culture, a key challenge persisted: teams couldn’t act on what they couldn’t see.
Supervisors couldn’t be everywhere at once, and lagging indicators like audits or incident reports weren’t enough to identify recurring safety risks or the day-to-day inefficiencies impacting site flow. Congested layouts, unclear traffic routes, and missed handoffs between teams often went unnoticed. What the company needed was real-time, site-specific insight to drive proactive, high-impact changes to both safety and operational performance.
“We get to see what’s actually happening on the floor. Then, based on the data, we target changes where they’ll have the most operational impact.”
A Proactive Approach to Safety and Operations
Protex AI was implemented within the company’s existing EHS and operations systems to surface patterns the team couldn’t see before. By integrating with on-site CCTV, the platform uncovered previously hidden issues, from unsafe pedestrian-forklift interactions to inefficient site pathways.
At several sites, path mapping, heatmaps, and timelapse visualizations helped identify congestion points and issue areas. These insights led to layout changes that enhanced both safety and efficiency.
At a site in North America, heatmaps and timelapse footage revealed heavy traffic and unsafe overlap. Within days, the team rerouted traffic and added visual cues on the floor.
In Southeast Asia, one site redesigned a U-path flagged as a high-risk intersection. Path mapping data prompted the team to re-route forklifts and introduce hand-operated pallet jacks instead. The change improved both safety and flow in a high-traffic area.
“Being able to show a clip or a heatmap changes the conversation. It’s not just data; it’s something actionable we can point to and fix.”
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Making Data Part of the Operational Fabric
Following early success in safety and flow improvements, the company is scaling Protex AI across 10+ global sites. Each deployment is locally tailored, but the goal remains the same: make risk visible, measure bottlenecks, and drive repeatable improvements.
Crucially, Protex AI insights are used to empower, not monitor teams. Data acts as a shared language that aligns operations, EHS, and frontline workers around continuous improvement.
The results so far:
Data-backed operational changes: High-risk and inefficient zones are redesigned before incidents occur
Greater frontline engagement: Teams co-own improvements using shared insights
“We’re not guessing anymore. We’re not waiting on an incident to act. Protex helps us see it, show it, talk about it, and fix it together.”
