• Holistic Data Coverage:
  • Speed profiles (real-time and historical).
  • Harsh breaking.
  • Roll/pitch.
  • Accelerations.
  • Seatbelt compliance records.
  • Fatigue and distraction alerts.
  • Smoking alerts.
  • Phone usage alerts.
  • Engine hours, idle times, and odometer readings.
  • GPS-based truck routes and last known locations.
  • Vehicle battery levels and CPU performance statistics.
  • AI-detected behavioural trends, anomalies, and efficiency insights.
• Integrated AI and Vehicle Data:
  • Shellshock AI integrates vehicle telemetry with advanced AI imaging insights, providing a complete operational picture.
  • AI models refine themselves over time, delivering increasingly accurate reports that incorporate behavioural patterns, safety risks, and performance metrics.
• Dynamic, Real-Time Dashboards:
  • Comprehensive dashboards offering real-time visibility of vehicle performance, driver behaviour, and AI-generated safety insights.
  • All dashboard information is captured in reports, ensuring no critical data is overlooked.
• Customizable Reporting Outputs:
  • Tailored reporting formats to meet site-specific operational requirements and compliance standards.
  • Exportable dashboards and analytics for transparent stakeholder communication.
• Operational Intelligence:
  • Long-term data storage and trend analysis, enabling predictive insights for risk mitigation.
  • Reports support continuous improvement initiatives by highlighting key performance indicators and operational inefficiencies.

Shellshock VIS identifies incidents and records key details such as:

• Video of incident
• Description of incident
• Vehicle ID
• Location
• Time

• The system categorizes the incident based on severity and operational impact.
• Historical data is analyzed to detect behavioural trends requiring further action.

• An in-built audio system triggers a clear, calm alert in the driver’s local language, specifying:
  • The nature of the detected incident (e.g., fatigue warning, speeding alert, harsh braking).
  • Explicit corrective action instructions (e.g., “Please pull over and call supervisor”).
• A real-time pop-up notification appears on the in-vehicle screen.

Optional addition: The driver must acknowledge the alert and complete the prescribed corrective action to resume operations.

Every incident is logged automatically into the system dashboard with the following details:

• • Driver Information: Full ID, license number, and safety compliance history.
  • Location Details: Accurate GPS coordinates with route mapping.
  • Time and Date Stamps: Precise timestamps of when the incident occurred.
  • Incident Classification: Categorized by risk level (e.g., low, moderate, high).

Escalation thresholds (e.g., repeated speeding or fatigue warnings) are defined in collaboration with HSEQ managers.

• Alerts escalate automatically based on configured criteria:
  • First-level notifications to immediate supervisors.
  • Higher-level alerts to operational management after repeated infractions.
• Escalation paths are adjustable to fit organizational safety standards.

Real Example of Customer Escalation Workflow:

• The supervisor accesses the incident summary through a secured portal.
• Contact with the driver is established, and additional corrective measures are discussed (e.g., mandatory rest period, vehicle inspection).
• Supervisors document all responses and close the incident loop once corrective measures are implemented.
• Reports are archived for compliance verification and continuous safety improvement.

• Critical incidents are defined by severe, high-risk situations, including but not limited to:
  • Vehicle rollover or flipping.
  • High-impact collisions involving external factors or infrastructure.
  • Manual activation of the emergency switch by the driver in life-threatening scenarios.
• Upon detection, the system:
  • Captures video of the incident.
  • Engages redundant communication channels, such as satellite and cellular networks, to guarantee uninterrupted data transmission.
  • Activates fail-safe protocols that ensure data integrity even in high-impact conditions.

Immediately after incident detection:

• The system plays a calming, pre-recorded message designed to:
  • Reassure the driver that emergency protocols have been successfully activated.
  • Inform the driver that all relevant emergency stakeholders have been notified and assistance is on the way.
• If possible, two-way audio communication is established between the driver and the central monitoring centre to:
  • Assess the driver’s physical and mental state.
  • Provide step-by-step survival guidance until help arrives.

• Real-time, simultaneous alerts are sent to:
  • On-duty supervisor(s) responsible for the fleet.
  • Emergency services equipped to handle the specific nature of the incident.
  • Internal emergency response teams trained in rapid deployment.
• Notifications include comprehensive incident data:
  • Vehicle and driver information.
  • Location and timestamp of the event.
  • Categorisation details and severity level.
  • Video footage or data evidence linked for supervisor review.
• The dashboard provides real-time visibility for operational teams and supervisors, capturing:
• All VIS data and AI imaging insights for a complete operational overview.

• Emergency Services Response:
  • Mobilisation decisions are made based on precise GPS data.
  • Rapid deployment of medical teams, firefighting units, or extraction specialists as required.
• Supervisor Coordination:
  • Verifies the driver’s condition via real-time communication.
  • Coordinates with internal teams for additional on-ground support.

• System Logging:
  • The system captures:
    • A complete, end-to-end timeline of parameters leading to an accident.
    • All stakeholder interventions, including timestamps and action details.
• Post-Incident Analysis:
  • Detailed reports are generated for:
    • Compliance verification against regulatory standards.
    • Training purposes to refine emergency response protocols.
  • Reports are archived securely for future reference and legal compliance.

Monitor forklifts, cars, trucks, and other machinery to ensure safe operating speeds and avoid accidents.

• Ensure safe operating speeds in high-traffic zones, reducing the risk of collisions and near-misses.
• Detecting speeding violations in real-time and trigger alerts for corrective action.
• Track vehicle movement to optimize routing, reduce congestion, and prevent unauthorized use.
• Integrate with geofencing to enforce speed limits in different areas of your facility (e.g., slow zones near pedestrian walkways).

Case Study - Sulphur Pad | Incitec Pivot

"SAPHI made my idea into a reality and overcame the challenges set. A big thank you to Cameron and Isaac from Saphi."

Dellis Irwin | Processing Engineer at Incitec Pivot Fertilisers

The Challenge

Incitec Pivot faced frequent fires on sulphur pads, with their existing thermal imaging system plagued by false positives caused by heavy machinery exhaust.

The Solution

Custom AI models to filter out non-critical heat sources, focusing on genuine risks. This reduced false positives and added new safety capabilities, such as tracking personnel and vehicles on-site.

The Outcome

• Reduced False Alerts: Accurate detection minimised distractions.
• Enhanced Monitoring: Broader safety oversight improved operational safety.
• Reliable Operations: A tailored, effective system transformed site safety standards.

Incitec Pivot now operates with confidence, leveraging AI-driven safety in a high-risk environment.

Asset Tracking – Keep tabs on high-value tools, raw materials, and equipment to reduce loss and improve utilisation.

• Track high-value tools, raw materials, and equipment in real time to prevent loss, theft, or misplacement.
• Monitor usage patterns to identify underutilised assets and optimise resource allocation.
• Set geofences to ensure equipment stays within designated areas, preventing unauthorised movement.
• Receive instant alerts when assets are left idle for too long, moved unexpectedly, or require maintenance.

• Real-Time Underground Vehicle Monitoring: Tracks driver and passenger behaviour, including seatbelt compliance and fatigue levels, with instant in-cab alerts for unsafe behaviour.
• Incident Detection and Response: Identifies slips, trips, and falls underground with rapid-response alerts, enhancing safety in confined and isolated spaces.
• In-Vehicle Underground Insights: Tracks driver and passenger behaviour, including seatbelt compliance, distraction, and fatigue levels.

AI detects whether workers are wearing required safety gear (helmets, vests, gloves) in real-time.

• Ensure PPE compliance in real time – AI automatically detects if workers are wearing required safety gear such as helmets, vests, gloves, and eyewear.
• Instant alerts for non-compliance, allowing supervisors to address risks before they lead to incidents.
• Monitor high-risk areas to ensure strict adherence to PPE requirements where it's most critical.
• Automate reporting to track compliance trends and improve workplace safety enforcement.

Instant alerts for falls, reducing response time and improving workplace safety.

• Instant alerts for falls, ensuring a rapid response to accidents—critical for lone workers and high-risk tasks.
• Detects slips, trips, and falls in real time, reducing delays in medical assistance.
• Automatically notifies supervisors or emergency teams when a worker is unresponsive after a fall.
• Enhances safety in isolated work areas, where immediate help may not always be available.

Ensure personnel and vehicles don't stray into danger zones.

• Ensure personnel and vehicles stay within designated safe zones, preventing unauthorised access to hazardous areas.
• Real-time alerts when workers or equipment enter restricted zones, allowing immediate corrective action.
• Geofencing and AI-powered monitoring to enforce safety protocols without manual supervision.
• Reduce accidents and compliance breaches by automatically tracking movement in high-risk areas.

Perimeter Security Monitoring – Mining sites are often located in remote areas, making them vulnerable to trespassing, theft, and vandalism. Traditional security systems only capture footage after an incident, offering no real-time prevention.

Shellshock AI provides proactive security by:

• Detecting unauthorized access as it happens, not after
• Identifying suspicious behaviour near critical assets like stockpiles, fuel storage, and equipment yards
• Sending instant alerts to security teams for immediate response
• Operating 24/7, even without connectivity, ensuring protection at all times

This means fewer disruptions, lower security costs, and maximum protection for both people and assets—no matter how remote the site.

Not every manufacturing environment is the same, and off-the-shelf AI models don’t always capture the unique risks and inefficiencies of your operation. If a specific safety or efficiency parameter isn’t covered, SAPHI can develop a custom AI model trained on your facility’s data, equipment, and workflows.

• Tailored to Your Operations – Whether it’s detecting specialised safety risks, monitoring unique production metrics, or identifying environmental hazards, our AI adapts to your exact requirements.
• Integration – Custom models plug directly into your existing camera network and infrastructure, meaning no additional hardware investment.
• Scalable & Future-Proof – As your operations evolve, your AI can evolve too, with remote updates ensuring continued relevance and accuracy.
• Beyond Standard Safety & Efficiency – From fire detection in hazardous zones to predictive failure analysis for unique machinery, SAPHI’s in-house AI team can build models for even the most complex challenges.