How AI and digitalization are creating safer workplaces in the 21st century

Did you know World Day for Safety and Health at Work, set up by the International Labour Organization (ILO) in 2003, and the International Commemoration Day for Dead and Injured Workers, set up in 1966 by trade unions, are held on the same day each year, April 28th? They are - and the reason is sobering: the ILO estimates that annually nearly 3 million people die from work-related incidents and that about 395 million workers experience non-fatal work injuries. We asked two Kiwa experts about some of the key developments in this sector.

Good news

Against that alarming backdrop, here’s some good news: developments in AI and digitalization are having a remarkable impact in preventing workplace injuries and improving overall working conditions. In short, according to Jonas Van hove, Global Business Sector Leader - Digital & Cyber Solutions at Kiwa, ‘Due to investment in digital technologies, such as, AI, robotics, and IoT workplaces have become significantly safer in the 21st century​.’

Robots, AI and IoT

Robots are increasingly performing dangerous tasks and reducing the exposure of humans to hazardous settings. AI-powered systems performing real-time monitoring can detect hazards early, reducing risk. Extended and virtual reality are transforming worker training programmes with immersive simulations for hazard recognition and emergency response. The latest tools include smart Personal Protective Equipment (PPE), such as hard hats or safety vests fitted with Internet of Things (IoT) solutions, or environmental sensors providing instant alerts. ‘And, amazingly’, Jonas adds, ‘AI doesn’t just monitor for hazards, it learns and adapts with every incident it records. By analysing patterns in historical and real-time data, AI can predict where and when risks are most likely to occur. AI can spot early warning signs of equipment problems, such as unusual vibrations, and by analysing past inspection and maintenance records, it can also predict where future issues are likely to occur. This allows maintenance teams to address issues before they lead to failures. With this information, safety managers can develop targeted safety training programmes, implement more effective safety protocols and allow maintenance teams to address issues before they lead to failures.'

Drones

Drones are another example of technology’s positive impact on safety at work. They are being used more and more to perform dangerous inspections of infrastructure, from wind turbine blades to storage tanks. These aerial robots, powered by advanced AI-models, can access and scan confined spaces or high-altitude locations without the need for scaffolding, significantly reducing risk for human inspectors. AI analyses the data captured by the drones to detect cracks, corrosion, or other anomalies. And expert inspectors still play a crucial role: they review and validate the AI findings, apply their experience to complex cases, and make informed decisions on necessary repairs. AI enhances human expertise, helping inspectors work faster, more safely, and with greater precision, all while minimising facility downtime.

Digital solutions strengthening safety

At Kiwa, digital innovation is driven by a strong commitment to making workplaces safer and more resilient across industries like offshore wind, construction, manufacturing, and pharmaceuticals. Tools like Digi-Tags

allow workers to instantly access verified, up-to-date equipment information during e.g. a Last Minute Risk Analysis, supporting faster, safer decisions on site. For instance, Vestas Offshore reduced manual inspections and boosted safety with Digi-Tags, while a pharmaceutical company strengthened equipment traceability.

Through digitalisation, companies gain faster insights into risks, strengthen preventive action, and empower employees to make safer decisions in real time. This focus translates into practical solutions such as the Impact Platform and UNO solution, which support Health, Safety, Environment, and Quality (HSEQ) management with mobile reporting of incidents and hazards, predictive monitoring, and AI-powered risk detection. Similarly, PPI Quality & Engineering, a Kiwa company, offers the Quality Assurance Reporter (QAR tool that helps organisations systematically track inspections and ensure quality assurance throughout critical projects. Together, these tools embody Kiwa’s mission to use technology to create safer working environments and help clients stay ahead of tomorrow’s challenges.

Not all good news

It’s not all good news though. Digitization, including surveillance and work intensification, brings with it the risk of mechanical failures. It also poses ergonomic and physical risks - think, for example, of noise, visual strain or balance issues - as well as psychosocial risks, such as cognitive overload or isolation. There are also questions around privacy protection. Proactive policies are needed to continue to address these new risks. The recently published European AI act and the new Machinery Regulation (to be applied from 2027) already are an important step forward, considering the specific risks related to the emerging technologies such as AI and autonomous (mobile) machinery. On top of that, cybersecurity has become a major focus in Europe for digital products and services.

Over 130,000 accidents

‘Another cause for concern’, says Philip Pierloz, Product Manager Safety of Machinery at Vinçotte, ‘is that in all the excitement around the benefits of digitisation we take our eye off the ever-present and unrelenting safety and health risks around machinery.’ In Belgium, where Philip is based, no less than 132,009 occupational accidents were recorded in 2023, with nearly 5% related to machinery and equipment, such as fixed conveyor belts and sawing machines. Half of the injuries involved hands and fingers and eight injuries were fatal. This means that an addition to the loss of a human life, an average of 80 full-time employees were absent that year. Philip continues, ‘Despite the extensive legal framework in place to ensure machine safety in Europe, our experts at Vinçotte still observe during machine safety inspections that many machines present significant safety risks. Lack or insufficient guarding of moving parts is the most common violation. Over 30% of violations or risks can be directly or indirectly attributed to this.’ Part of these violations are due to insufficient maintenance, lack of safety checks or manipulations during use. But what is more remarkable is that in 70% of these cases the machine never reached the expected safety level. This emphasises the importance of safety management for machinery during their whole lifetime from acquisition to coming into service to production and maintenance.

Technology is helping us to manage these risks. But accessing tech is not always easy, notes Jonas. Barriers companies may face in implementing AI and digital solutions can include high initial costs, the limited quality of data, and data privacy concerns. Also, the time required to train AI models and therefore mitigate possible hallucinations, as well as the need for specialised skills, can make the transition tough‘

However, as technology becomes more accessible and AI systems are refined, Philip and his colleagues do expect these barriers to go down, paving the way for broader AI adoption in safety management. Jonas Van hove summarizes, ‘Investing in advanced safety technology not only protects people – it also drives efficiency, cost savings, and overall performance improvements for companies.’