Case Studies

Real-World Safety. Measurable Results.

See how leading industrial companies use the IndoorNavi Safety System to protect their workforce and reduce operational risk across their facilities.

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Global Manufacturer
Global Manufacturer Mass Production

Automated Collision Prevention in a High-Volume Manufacturing Plant

A global mass-production leader with heavy forklift traffic (over 450,000 km per year) needed a proactive solution to eliminate near-miss incidents. We deployed a custom, non-invasive safety ecosystem that automatically enforces speed limits in critical zones without disrupting daily operations.

Day 1
Impact According to the facility's EHS Manager, the system automatically decelerated a forklift, preventing a potential collision on the very first day of activation.

The Challenge

The facility operates with hundreds of pedestrians and a fleet of dozens of forklifts sharing a massive space. Despite a strong safety culture, excellent track record, and regular training, occasional "near-miss" situations still occurred due to human fatigue and blind spots. Instead of waiting for an incident, the plant’s leadership sought a proactive, highly flexible, and non-invasive system to completely eliminate the risk of forklift-pedestrian collisions and infrastructure damage in high-traffic areas.

Our Solution

Following a rigorous audit and digital simulations, we deployed a custom-tailored UWB ecosystem. We equipped the forklift fleet with approximately 30 Vehicle Tags and established intelligent safety zones using 8 Anchor Tags, 11 Fixed Tags for infrastructure protection, and 5 Intelligent Gates. Now, when a forklift enters a critical zone or crosses a gate, the system automatically forces a speed reduction to a safe 5 km/h. The entire installation was "Plug & Play" and non-disruptive, requiring no complex wiring or wall alterations.

Key Results

Day 1
Impact According to the facility's EHS Manager, the system automatically decelerated a forklift, preventing a potential collision on the very first day of activation.
<1 Week Full deployment timeline for the complete safety ecosystem across the massive facility.
Zero Production downtime. Rotational installation ensured the forklift fleet was never pulled from operation, safeguarding operational continuity.
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GLOBAL MANUFACTURER
GLOBAL MANUFACTURER Infrastructure Protection

Eliminating Vertical Blind Spots in High-Bay Warehousing

A precision components manufacturer faced a critical risk: high-reach VNA forklifts operating perilously close to vital overhead utility pipelines. We deployed a custom UWB proximity shield that provides centimeter-level vertical alerts, preventing catastrophic infrastructure damage and costly production halts.

€10k
to 50k Avoided in hourly unplanned downtime costs by neutralizing the threat of critical utility line breaches.

The Challenge

The plant utilizes specialized VNA (Very Narrow Aisle) forklifts with elevating cabins to maximize warehouse capacity. However, judging the exact vertical distance between the rising cabin and vital overhead utilities – such as high-pressure water and heating pipes – created dangerous vertical blind spots. A single misjudgment could rupture a pipeline, leading to ruined high-value inventory, damaged machinery, and unpredictable production downtime costing up to €50,000 per hour.

Our Solution

In collaboration with our strategic partner Falco, we designed a non-invasive, custom IoT shield. We installed Fixed Tags on critical overhead pipelines and equipped the high-reach forklifts with Vehicle Tags linked directly to high-visibility, in-cabin warning lights. Using precise UWB technology, the system continuously monitors vertical clearances. The moment a rising cabin breaches the pre-configured safety buffer, the operator receives an immediate, unmissable alert to halt movement long before making physical contact.

Key Results

€10k
to 50k Avoided in hourly unplanned downtime costs by neutralizing the threat of critical utility line breaches.
100% Operational continuity secured without reducing high-bay warehouse throughput or daily logistics.
In partnership with
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Logistics Leader
Logistics Leader Hybrid AI & UWB Safety

AI Vision & UWB Integration: Total Protection in Heavy Logistics

A busy logistics hub needed a failsafe way to protect both tagged workers and untagged visitors around heavy machinery. We deployed a hybrid system integrating our UWB Vehicle Tags with smart AI cameras to instantly recognize human shapes and force automatic vehicle deceleration.

100% Coverage. Complete safety net achieved by detecting both tagged employees and untagged visitors via smart human-shape recognition.

The Challenge

Operating a high-volume warehouse with heavy forklifts and frequent external visitors creates critical blind spots. While standard UWB tags effectively protect internal staff, management needed a zero-tolerance safety net for untagged pedestrians, contractors, and workers who might forget their wearables. The solution had to reliably recognize human figures in real time without generating false alarms from static warehouse obstacles.

Our Solution

We engineered a pioneering hybrid safety architecture. Forklifts were equipped with our Vehicle Tags integrated directly with smart AI-powered vision cameras. The system continuously monitors the perimeter: UWB handles precise distance ranging for tagged staff, while the AI camera dynamically detects human shapes in blind spots. When any pedestrian is detected, the system instantly triggers in-cabin acoustic alerts and forces automatic vehicle deceleration.

Key Results

100% Coverage. Complete safety net achieved by detecting both tagged employees and untagged visitors via smart human-shape recognition.
Zero False Alarms. Advanced AI vision algorithms reliably differentiate human silhouettes from static warehouse infrastructure, pallets, and shelving.
I/O Automated. Seamless hardware integration triggers immediate in-cabin buzzers and forces safe vehicle deceleration without operator intervention.
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The Experts Securing Your Facility

Mateusz Kuszner, PhD, Eng.

Mateusz Kuszner, PhD, Eng.

CEO

Doctor of Physics bridging academic research with industrial entrepreneurship. As CEO, this Intel Global Challenge finalist leverages deep expertise in embedded systems to pioneer advanced positioning platforms for GPS-denied environments.

Bartosz Reichel, PhD, Eng.

Bartosz Reichel, PhD, Eng.

CTO

Doctor of Engineering combining academic rigor with scalable industrial innovation. As CTO and Intel Global Challenge finalist, he brings profound architectural expertise in M2M systems and .NET technologies to build robust digital ecosystems.

Our core strength lies in our multidisciplinary team of software developers, backend engineers, and hardware specialists, all working in synergy to deliver your project.

+ 15 Specialized Engineers