Industrial Safety · MI-IS-01
Intelligent Helmet for Impact, Fall & Proximity
Smart helmets detect impact, fall and helmet-off, warn within 3 m of a moving forklift, and raise SOS to a supervisor in seconds.
Industrial Safety · MI-IS-01
A clip-on sensor turns the helmet your workers already wear into a safety device: impact and fall detection, helmet-on/off, an SOS button and a proximity warning near moving forklifts. Five helmets, two vehicle beacons, one gateway.
- ₹1,00,500pilot BOM · hardware only
- 4 – 6 daysto a live pilot
- Intermediateintegration level
- 3validated providers
Why helmet incidents are found too late
The problem
Head injuries, falls and forklift strikes are recorded after the fact, on a form. The helmet is on every head in the plant and carries no intelligence at all. When a worker goes down in a quiet corner of the yard, the first person to know is whoever walks past.
- No live signal when a worker falls, is struck or is not moving
- Forklift-pedestrian near-misses are never captured, only the collisions
- Helmet compliance is enforced by supervisors and cannot be proven for audits
- Lone areas — yards, tank farms, night shifts — have the longest response times
The solution
A helmet-mounted sensor module with an IMU detects impact, fall and helmet-off, carries an SOS button, and listens for BLE beacons fitted to forklifts and cranes. Events go over LoRaWAN to a safety dashboard that escalates by SMS or push to the supervisor with the worker's name and last zone.
- Impact, fall, no-motion and helmet-off events with a timestamp and zone
- Proximity warning to the wearer within ~3 m of a beaconed vehicle
- One-press SOS with escalation to a supervisor in seconds
- Compliance and near-miss reports per shift for safety audits
Validated service providers
Validated by TwoElectrons and ranked by validation score: verified credentials, completed jobs on the platform and client ratings.
- Sample Provider P — Mumbai · Connected PPE & helmets · ★ 4.8 · 8 jobs
- Sample Provider Q — Vadodara · Gas safety & lone worker · ★ 4.7 · 10 jobs
- Sample Provider R — Bengaluru · Wearables & worker health · ★ 4.6 · 5 jobs
Provider listings are samples pending live registrations.
Pilot BOM and cost
Reference hardware to run the pilot. Unit costs are indicative Indian market prices for the component class.
| Qty | Item | Unit cost | Line |
|---|---|---|---|
| 5× | LoRaWAN / BLE helmet sensor module IMU impact & fall detection, helmet-on/off, SOS, clip-on | ₹15,200 | ₹76,000 |
| 2× | BLE proximity beacon for vehicles mounted on forklift / crane | ₹2,500 | ₹5,000 |
| 1× | LoRaWAN Bluetooth gateway | ₹13,500 | ₹13,500 |
| 1× | Safety dashboard with escalation SMS / push to supervisor; free tier | Free tier / open source | — |
| 5× | Helmet mounting kit & charging dock | ₹1,200 | ₹6,000 |
| Pilot BOM total | ₹1,00,500 |
POC BOM cost only — hardware for a pilot. Installation, integration and provider services are quoted separately. Request for Quote
How the intelligent helmet works
- Fit. Clip a sensor module to five helmets; mount BLE beacons on two forklifts.
- Cover. Place the LoRaWAN gateway to cover the pilot bay or yard.
- Configure. Set the escalation list: who gets SMS, push or a dashboard alert.
- Drill. Run a fall and an SOS drill; time the response from event to supervisor.
Pilot architecture
5× Helmet sensor modules (IMU · SOS · helmet-on/off) → 2× Vehicle BLE beacons (forklift / crane proximity) → LoRaWAN Bluetooth gateway (bay or yard coverage) → Safety cloud (event rules · escalation) → Supervisor dashboard (SMS · push · muster list)
Helmets hear the vehicle beacons directly (BLE) and report events via the gateway (LoRaWAN), so proximity warnings work even if the backhaul is down.
Business case: response time, near-misses, compliance
Ranges are typical figures reported for this class of solution; your pilot establishes the numbers for your plant.
- Seconds from fall to supervisor alert (versus minutes to hours when discovered by chance)
- 100% of near-misses captured (proximity events logged, not just collisions)
- Per shift compliance report (helmet-on time by worker and zone)
- < 1 week to a live pilot (five helmets, one gateway)
Who this is for: EHS / safety heads, Plant and yard managers, Steel, cement, logistics yards, Warehouses with forklift traffic, Construction and infrastructure sites, Night-shift and lone-worker areas.
Illustrative case study
Illustrative scenario · not a client reference
A steel service centre with a busy coil yard in Gujarat (illustrative)
Set-up. Five helmets for the yard crew, beacons on two forklifts, one gateway on the yard lighting mast. The safety officer received escalations on WhatsApp; the shift supervisor saw the live dashboard.
What happened. Over four weeks the system logged 31 forklift proximity events — none had been reported as near-misses before. A re-routed pedestrian walkway cut them to four the following month. One genuine fall was escalated in under 20 seconds.
- Pilot budget: ₹1,00,500 hardware
- Near-misses surfaced: 31 in 4 weeks
- Fall-to-alert: < 20 s
FAQ
Does it work with the helmets we already issue?
Yes. The sensor is a clip-on module for standard industrial helmets; no need to replace PPE.
Does the worker's location get tracked all day?
The pilot records zone-level presence and safety events, not continuous positioning. Data retention and who can see it are set with your EHS team.
What happens if the gateway loses connectivity?
Proximity warnings are helmet-to-beacon over BLE and keep working. Events are buffered and sent when the link returns.
How long does the helmet module battery last?
Typically a full week of shifts on one charge; the kit includes a charging dock for five modules.
What does the ₹1,00,500 cover?
Only the pilot hardware for five workers and two vehicles. Installation, integration with your ERP/HR and provider services are quoted after a Request for Quote.
