Industrial Safety · MI-IS-02
Wearable Fatigue, Heat-Stress & Vitals Monitoring
Wearables stream heart rate, skin temperature and activity; a per-worker heat-stress index triggers a mandatory cool-down alert.
Industrial Safety · MI-IS-02
Industrial wearable bands for five workers, WBGT environmental sensors in two hot zones and a worker-health dashboard that computes a heat-stress index per worker and enforces cool-down breaks.
- ₹91,500pilot BOM · hardware only
- 4 – 6 daysto a live pilot
- Intermediateintegration level
- 3validated providers
Why heat stress is found at the point of collapse
The problem
Furnace, foundry, kiln and summer outdoor crews work in heat that is measured, if at all, by a wall thermometer. Fatigue and heat stress show up as a collapse, a near-miss or a quality drop at the end of the shift, never as a warning.
- No individual heat-stress or fatigue indicator
- Breaks are by clock, not by the worker's condition
- Environmental readings are not linked to the people in the zone
- Heat-related incidents are recorded after the fact
The solution
Each worker wears an industrial band streaming heart rate, skin temperature and activity over BLE; WBGT sensors in the hot zones report wet-bulb globe temperature over LoRaWAN. The dashboard combines the two into a heat-stress index per worker, alerts the supervisor and the worker when a cool-down is due, and records exposure per shift with privacy controls.
- Heart rate, skin temperature and activity per worker
- WBGT per zone linked to who is in it
- Heat-stress index with mandatory cool-down alerts
- Shift exposure records with privacy controls agreed with HR
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× | Industrial wearable band / smart badge HR, skin temp, IMU, SOS, BLE | ₹9,500 | ₹47,500 |
| 2× | LoRaWAN WBGT / heat-index environmental sensor zone temperature & humidity | ₹14,000 | ₹28,000 |
| 1× | LoRaWAN Bluetooth gateway | ₹13,500 | ₹13,500 |
| 1× | Worker-health dashboard per-shift exposure, alerts, privacy controls | Free tier / open source | — |
| 1× | Charging dock & wrist/lanyard mounts | ₹2,500 | ₹2,500 |
| Pilot BOM total | ₹91,500 |
POC BOM cost only — hardware for a pilot. Installation, integration and provider services are quoted separately. Request for Quote
How wearable and WBGT monitoring works
- Wear. Issue bands to five workers in the hottest roles.
- Sense. Mount WBGT sensors in two zones; gateway covers both.
- Set. Agree the index thresholds and cool-down rule with EHS.
- Run. Two hot weeks; review alerts and break compliance.
Pilot architecture
5× Wearable bands + 2× WBGT sensors (HR · skin temp · IMU · WBGT) → LoRaWAN BLE gateway → Worker-health cloud (heat-stress index · rules) → EHS dashboard (alerts · exposure per shift)
Vitals and zone WBGT are combined per worker; alerts go to the band, the worker's supervisor and the dashboard.
Business case: incidents, breaks, exposure records
Ranges are typical figures reported for this class of solution; your pilot establishes the numbers for your plant.
- Minutes of warning before heat stress (instead of a collapse)
- Per worker exposure record per shift (for health files and audits)
- Condition-based breaks instead of clock (fewer incidents, steadier output)
- 4 – 6 days to a live pilot (five workers, two zones)
Who this is for: EHS and occupational health, Foundries, forging and heat treatment, Steel, glass and ceramics, Outdoor construction and utilities, Cold-storage crews (cold-stress variant), Any plant with hot-zone roles.
Illustrative case study
Illustrative scenario · not a client reference
A forging unit's hammer shop in the May heat in Rajkot (illustrative)
Set-up. Bands for five hammer operators, WBGT sensors at the furnace line and the hammer bay, cool-down alerts to the shift supervisor and a buzz on the band, thresholds set with the company doctor.
What happened. Cool-down alerts fired 3–4 times per worker per shift in the hottest week; the supervisor introduced a rotation that matched. No heat-related incident was recorded in the pilot month against two in the same month the previous year, and the exposure record supported a summer-shift policy.
- Pilot budget: ₹57,000 hardware
- Incidents (pilot month): 0 vs. 2 prior year
- Alerts per worker/shift: 3 – 4
FAQ
Is this health surveillance of workers?
The pilot is designed with EHS and HR: workers see their own data, supervisors see alerts, and retention and access are agreed up front. It is a safety tool, not performance monitoring.
How accurate are the vitals?
Wrist-based heart rate and skin temperature are indicative and reliable for trend-based alerts; they are not medical devices.
What is WBGT?
Wet-bulb globe temperature — the standard heat-stress index combining temperature, humidity, radiant heat and airflow, used in occupational health limits.
What does the ₹57,000 cover?
Five bands, two WBGT sensors and a gateway on a free-tier dashboard, plus charging docks. Policy design, HR integration and provider services are quoted after a Request for Quote.
