Successful Story · Bridgestone EMEA Bari Plant
How to Integrate Safety, Efficiency, and Operational Continuity Every Day
A concrete path: AI-powered devices, real-time data, and people engagement to reduce risks and keep operations flowing.Context
At the Bridgestone plant in Bari, handling vehicles and pedestrians share operational areas with fast-paced rhythms. The goal is clear: reduce the risk of collisions and ensure the continuity of the flow, while valuing the contribution of all people.🎯 The Challenge
Preventing vehicle–vehicle and vehicle–pedestrian interferences in a dynamic and diverse context (forklifts, tow tractors, pallet trucks), while preserving operational continuity.💡 The Answer
Devices with artificial intelligence for detecting pedestrians and heterogeneous vehicles, access control for authorized use, electronic checklists, and data collection for continuous improvement.
🧭 The Method
Cross-functional involvement of maintenance, engineering, logistics, production, and workers’ representatives. Real-time insights to update the traffic plan and take action on critical intersections.Observed Results
- Operational continuity confirmed: no negative impact on vehicle performance according to field data.
- More aware operators thanks to alerts and contextual guidance supporting driving.
- Advanced traffic management: data to optimize layouts and manage high-density areas.
- Digital controls: trackable daily checklists, less paper, more timely and organized maintenance.
Voices from the Field
“The devices support the forklift operator and, thanks to the data, we can update the traffic plan in real time and act on critical points.”
“The flow analysis confirms operational effectiveness: a double benefit, greater safety and process continuity.”
“Electronic checklists and automatic alerts make maintenance more timely, reduce downtime, and facilitate audits.”
Why It works
- Real prevention: it starts with the analysis of reports and observations collected directly in the field, valuing the contributions of those who work daily in the departments, to identify and reduce risks before they can cause accidents.
- Concrete plant data: every decision is based on precise and measurable information gathered within the specific operational context of the plant, avoiding reliance on assumptions or generic estimates.
- Targeted flow optimization: data makes it possible to act precisely on the most critical points, improving internal traffic and reducing interference between vehicles and pedestrians.
- Integration with digitalization: electronic checklists and automatic data collection make maintenance faster, control management more organized, and reporting simpler both internally and for audits.
- Cross-functional and ongoing involvement: the project draws strength from the joint work of technical and production departments and workers’ representatives, creating a shared and lasting commitment that makes safety an integral part of the organization.
- Adaptability to context: the adopted solutions are flexible and tailored to the specific needs of the plant, so they integrate without hindering production activities.
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