Use Case: How GERTY AI Assist Could Transform Safety Management in Manufacturing

This use case explores how GERTY AI's Assist module could help manufacturing companies address persistent safety challenges across multiple facilities. See how this solution could transform safety management, overcome common challenges, and deliver remarkable results.

Company Background

Manufacturing companies with operations across multiple regions face significant challenges in maintaining consistent safety standards and practices across diverse locations and regulatory environments.

Despite having dedicated EHS teams and established safety protocols, many manufacturers struggle with:

• Inconsistent safety performance across facilities
• Difficulty keeping up with changing regulations in multiple jurisdictions
• Time-consuming manual safety reporting processes
• Limited ability to identify emerging safety risks proactively
• Challenges in providing timely, expert-level safety guidance to frontline supervisors

The Decision to Implement GERTY AI Assist

After evaluating several EHS solutions, a manufacturing company might select GERTY AI's Assist module based on its domain-specific expertise in manufacturing safety, multilingual capabilities, and ability to integrate with existing safety management systems.

"What would impress us most about GERTY AI is its deep understanding of manufacturing safety challenges and regulatory requirements," explains a Global EHS Director. "Other AI solutions have general capabilities, but GERTY AI demonstrates specific knowledge of our industry's safety standards and best practices."

Implementation Process

A manufacturing company could follow a structured implementation approach, working closely with the GERTY AI implementation team:

Phase 1: Pilot Implementation (Month 1-2)

The implementation could begin with a pilot at the company's largest facility. This phase would include:

• Integration with the existing safety management system
• Configuration of GERTY AI Assist to incorporate specific safety policies and procedures
• Training for the core EHS team and selected safety champions
• Initial use cases focused on regulatory compliance questions and procedure development

Phase 2: Expansion to Regional Hubs (Month 3-4)

Following a successful pilot, the company could expand GERTY AI Assist to regional hub facilities:

• Localization for regional regulatory frameworks
• Additional language support for non-English speaking facilities
• Training for regional EHS teams
• Expanded use cases to include risk assessments and incident investigations

Phase 3: Full Deployment (Month 5-6)

The final phase involved deployment across all remaining facilities:

• Access extended to all safety professionals and frontline supervisors
• Integration with GMC's learning management system for safety training support
• Development of facility-specific knowledge bases
• Establishment of continuous feedback and improvement processes

How GERTY AI Assist Works in Practice

GERTY AI Assist could become an integral part of daily safety operations. Here's how different stakeholders might use the system:

Safety Professionals

Safety professionals could use GERTY AI Assist to:

• Research regulatory requirements: "I need to understand the differences between OSHA and EU requirements for confined space entry. GERTY AI could provide a detailed comparison in minutes, something that would otherwise take hours of research." - Safety Manager
• Develop safety procedures: "When creating a new lockout/tagout procedure for a new production line, GERTY AI could help draft the initial procedure based on existing templates and best practices, which could then be customized for specific equipment." - Corporate Safety Director
• Conduct risk assessments: "GERTY AI could help identify potential hazards that might be overlooked. For a process change, it might suggest considering noise exposure risks that weren't initially on the radar." - Plant Safety Specialist

Frontline Supervisors

Supervisors could access GERTY AI Assist through both desktop and mobile interfaces to:

• Get real-time guidance: "When a contractor arrives without proper PPE, I could use GERTY AI to quickly confirm requirements and the appropriate actions to take." - Production Supervisor
• Prepare for safety talks: "GERTY AI could help prepare for daily toolbox talks by finding relevant topics based on recent near-misses or seasonal hazards." - Team Leader
• Respond to employee questions: "When employees have safety concerns, supervisors could provide immediate, accurate information rather than saying 'I'll get back to you.'" - Shift Supervisor

EHS Leadership

At the leadership level, GERTY AI Assist could support strategic safety initiatives:

• Policy harmonization: "GERTY AI could help harmonize safety policies across global operations while ensuring compliance with local regulations." - Global EHS Director
• Training program development: "GERTY AI could help identify gaps in training programs and develop more effective, targeted safety training." - Corporate Training Manager
• Audit preparation: "Before regulatory inspections or corporate audits, GERTY AI could help review requirements and ensure full preparation." - Compliance Manager

Results and Benefits

After six months of implementation across all facilities, a manufacturing company could expect to see significant improvements in several key areas:

Safety Performance Improvements

• 23% reduction in recordable incident rate across all facilities
• 35% increase in near-miss reporting, indicating improved safety awareness
• 41% reduction in repeat safety violations
• 28% improvement in safety audit scores

Operational Efficiency Gains

• 67% reduction in time spent researching regulatory requirements
• 52% faster development of new safety procedures and policies
• 43% reduction in safety documentation review time
• Estimated 1,200+ hours per month saved across the safety team

Knowledge Democratization

• 89% of supervisors report increased confidence in handling safety issues
• 76% increase in safety questions resolved at the supervisor level without escalation
• More consistent safety practices across all facilities, regardless of location
• Improved knowledge transfer between experienced and newer safety professionals

Challenges and Lessons Learned

While the implementation was largely successful, GMC encountered several challenges:

Initial Skepticism

"Some experienced safety professionals might initially be skeptical about an AI system providing safety guidance," notes a safety leader. "This could be addressed by emphasizing that GERTY AI is a tool to enhance their expertise, not replace it, and by demonstrating its ability to provide accurate, relevant information."

Data Integration

Integrating GERTY AI with existing systems might require more effort than initially anticipated, particularly for facilities with older safety management systems. The implementation team could work closely with IT to develop custom connectors where needed.

Cultural and Language Considerations

For international facilities, cultural differences in safety approaches and language nuances might present challenges. Companies could work with GERTY AI to refine the system's understanding of regional terminology and practices.

Future Plans

Building on the success of the initial implementation, a company might consider several ways to expand their use of GERTY AI:

• Extending access to additional roles, including maintenance teams and contractors
• Implementing the GERTY AI Store module to improve safety document management
• Exploring the GERTY AI Automate module for safety inspection workflows
• Developing custom training for new employees using GERTY AI's knowledge base

Conclusion

This use case demonstrates how domain-specific AI could transform safety management in complex manufacturing environments. By providing instant access to expert-level safety guidance, streamlining compliance processes, and supporting consistent safety practices across diverse facilities, GERTY AI Assist could help manufacturing companies achieve significant improvements in both safety performance and operational efficiency.

GERTY AI could become an indispensable part of a manufacturing safety program. It's like having a safety expert available 24/7 for every member of your team, helping build a stronger safety culture and ultimately protecting your most valuable asset—your people.

For more information on how GERTY AI could transform your organization's safety management, contact us for a personalized demonstration.