Experience implementing computer vision to detect line-of-fire exposure during copper cathode handling: false positives, alerts, and lessons learned [Chile]

[u/NoOwl6690]

We implemented computer vision in a copper cathode handling area to detect when personnel entered a line-of-fire zone. The goal was to provide an early warning to operators and the control room, without replacing in-person supervision.

We used existing cameras, defined exclusion zones, and configured alerts for the control room. The main challenges were false positives during shift changes, routine maintenance movements, and changes in lighting conditions.

What helped most was establishing a clear response protocol, using local alerts, and reviewing events weekly with supervisors.

We are still working on better distinguishing authorized maintenance access from unsafe entry into the zone.

For those who have implemented computer vision in industrial safety: what criteria have you used to tune false positives and design alert workflows?