Do we have to replace our cameras to add AI?

Almost never. Camera-agnostic analytics run on existing IP camera fleets, including older hardware. On the consultation call we review what you have and only recommend new cameras where the existing equipment cannot carry the resolution or codec the analytics need.

What does AI actually do on a production floor?

Two distinct jobs on the same camera feed. The safety and EHS system handles PPE and restricted-zone detection, forklift-pedestrian proximity, slip-and-fall, and after-hours intrusion. The operations system handles line counting, cycle-time and throughput modeling, occupancy, dwell, and bottleneck detection. Most sites start with one, prove it, then add the other.

Will the alerts overwhelm my supervisors?

Not if it is tuned right. We start narrow (two or three event types) and tune on site so the model learns your floor, and only route alerts to supervisors once the false-positive rate is low. Most sites land at 3 to 7 actionable events per shift, not 60.

How much does adding AI cost?

The analytics tier is typically charged per camera per month for the cloud + analytics layer, so cost scales with how many cameras you point it at. The bigger line item is usually the network if switches and PoE need work. We give a defensible number after the free consultation.

How long before the AI is reliable?

It depends on your floor. We tune on site first: the model learns your camera angles, lighting, and traffic patterns, and alerts only route to supervisors once the false-positive rate is low enough that they treat them like any other dispatched event rather than noise.

Industry · Manufacturing AI

Run safety and operations off the cameras you already own.

Tec-Tel adds two kinds of AI to your existing floor cameras. A safety and EHS system: PPE, forklift-pedestrian proximity, restricted zones, slip-and-fall. And an operations system: line counting, cycle-time and throughput modeling, bottleneck detection. Same cameras, no rip-and-replace. We tune each on your floor, then stand behind it.

Start the conversation

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Call us855-577-0400

NDAA-compliant
Platform-agnostic
1,000+ deployments over 15 years

On site

we tune analytics before any alert goes live

3–7

actionable events per shift after tuning, not 60

No rip-and-replace

AI runs on cameras you already own

15+ yr

as a nationwide security integrator

§01 What the AI layer does

Two systems, one camera feed.

Two different jobs run on the same cameras: a safety and EHS system, and an operations-analytics system. Here's what your EHS leads and your plant managers each work with from day one.

→

Safety / EHS: PPE + restricted-zone detection. Hard hat, hi-vis, hot-work and chemical-zone exclusion. Tuned on your floor so EHS leads get 3 to 7 real events a shift, not an alert firehose nobody reads.

→

Safety / EHS: forklift-pedestrian proximity. AI flags near-misses between powered equipment and people before they become OSHA recordables. The most expensive production-floor incidents start here.

→

Safety / EHS: slip-and-fall + after-hours intrusion. Person-on-the-floor detection in monitored zones and after-hours-presence alerts. The clip is the evidence record when a claim or an incident review arrives.

→

Operations: throughput + cycle-time analytics. Object and people counting on the line: units per hour, cycle time by station, changeover duration. The same feed shows where the line actually loses its minutes, not where you assume it does.

→

Operations: occupancy, dwell + bottleneck detection. Dock-door throughput, line-station occupancy, and dwell modeled over time, so the bottleneck forming at 4pm Tuesday surfaces before the shift report would.

→

Plain-English footage search. Type "white box truck at dock 4 yesterday afternoon" and pull the clip in seconds. One search reaches every camera, with no scrubbing twelve hours of recordings.

§ How we work

Most sites already have cameras recording and nobody watching. We add the analytics layer on the fleet you own, tune it on your floor, and turn PPE and proximity events into alerts a supervisor actually actions. No new cameras.

How Tec-Tel works in manufacturing AI

§02 How a Tec-Tel AI deployment actually goes

Five steps. No alert firehose.

Assess the cameras you already own

Camera-agnostic AI runs on existing IP fleets, including older hardware. We tell you what carries the analytics and what doesn't, no rip-and-replace pitch.

Pick the right intelligence layer

Different sites need different models. We match the analytics (PPE, proximity, search, ops) to your floor, your risk, and your insurer's asks.

Start narrow

Two or three event types first (PPE, restricted-zone). Computer-vision alerts create alert fatigue if you turn everything on at once. Narrow, then expand.

Tune on site before go-live

The model learns your camera angles, lighting, and traffic. Alerts route to supervisors only after the false-positive rate is low enough to trust.

Review quarterly, expand deliberately

Quarterly reviews show what the system surfaced. New event types get added once supervisors are actioning what they already get.

§03 What a Tec-Tel deployment looks like

Three deployment shapes. Three different stacks.

No two floors need the same analytics. Here are the three shapes we deploy most, and what each runs.

Safety / EHS first

Site under insurance or OSHA pressure

→ PPE non-compliance, near-miss, and ergonomic-risk detection
→ Forklift-pedestrian proximity as the first model
→ Quarterly trend packets your insurer can read
→ Footage retention designed for a recordable inquiry

Operations / efficiency first

Site chasing throughput, not incidents

→ Line counting, cycle-time, and changeover analytics
→ Bottleneck and dwell modeling by station
→ Throughput dashboards a plant manager reads daily
→ Runs on the same cameras, no new sensors on the line

Multi-site standardization

Operator standardizing analytics across sites

→ One analytics platform, one tuning standard across sites
→ Central VMS, federated alerting per site
→ Consistent event taxonomy so site data is comparable
→ Phased rollout: prove on the first site, replicate

§04 Compliance buyers ask us about

Frameworks we build to.

OSHA

PPE, near-miss, and ergonomic-risk evidence. Quarterly reviewable footage and trend packets your insurer and your safety committee can read.

Insurance

Many carriers now ask for active monitoring or AI verification on industrial coverage. The analytics produce the documentation the underwriter wants.

NDAA Section 889

AI runs on the cameras, but if you sell to the federal government the cameras themselves must be 889-compliant. We flag and plan that.

Data governance

AI analytics run at the edge or in a segmented tenant. Footage and model data stay on a network separate from production systems.

Questions buyers ask us

FAQ

Do we have to replace our cameras to add AI?: Almost never. Camera-agnostic analytics run on existing IP camera fleets, including older hardware. On the consultation call we review what you have and only recommend new cameras where the existing equipment cannot carry the resolution or codec the analytics need.
What does AI actually do on a production floor?: Two distinct jobs on the same camera feed. The safety and EHS system handles PPE and restricted-zone detection, forklift-pedestrian proximity, slip-and-fall, and after-hours intrusion. The operations system handles line counting, cycle-time and throughput modeling, occupancy, dwell, and bottleneck detection. Most sites start with one, prove it, then add the other.
Will the alerts overwhelm my supervisors?: Not if it is tuned right. We start narrow (two or three event types) and tune on site so the model learns your floor, and only route alerts to supervisors once the false-positive rate is low. Most sites land at 3 to 7 actionable events per shift, not 60.
How much does adding AI cost?: The analytics tier is typically charged per camera per month for the cloud + analytics layer, so cost scales with how many cameras you point it at. The bigger line item is usually the network if switches and PoE need work. We give a defensible number after the free consultation.
How long before the AI is reliable?: It depends on your floor. We tune on site first: the model learns your camera angles, lighting, and traffic patterns, and alerts only route to supervisors once the false-positive rate is low enough that they treat them like any other dispatched event rather than noise.

Book a free assessment

See what the AI layer adds to your camera fleet.

Book a free consultation. The Tec-Tel team tells you what your existing cameras can carry, which analytics fit your floor, and what it costs.

Tell us how many sites you run and what's already in place. We'll show you what a build or upgrade looks like.
Straight answers from the team that does the work. We're platform-agnostic, so you get the system that fits your sites, not one brand's catalog.

Since 2010 · 1,000+ deployments nationwide · ISN-accredited

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What you're looking for, plus any details. We review it and follow up, usually the same day.

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