Applications of Engineering 4.0 to Improve the Safety of Metalworking Operators: The Ansaldo Energia Case

The paper describes how, on behalf of Ansaldo Energia Spa, a multidisciplinary team developed a methodology based on Industry 4.0 technologies, an approach that allows rescue teams to quickly intervene in the event of a mandown in isolated areas of the plant, where the unfortunate person would risk being found with significant delay and onsequent problems for his physical well-being. Under the supervision of the team, a highly specialized supplier created a suitable hardware and software device to achieve this outcome. Such a device can immediately warn rescue crews in real time as soon as an incident occurs, as well as geo-locate the man on the ground with exceptional precision. Once developed, the approach was standardized in a set of sequential and generic procedures in order to make it adaptable to any sort of firm, construction site, or workshop where a man-down event may happen. The methodology is set up as a real toolkit to protect operators from severe damage that can result from long waits for rescue teams, whenever operators experience negative events for their safety being them exogenous (fainting illnesses, heart attacks, epileptic attacks, strokes, etc.) or endogenous (accidents in the workplace).