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Smart digital systems make it possible to monitor working conditions in real time, predict emerging risks and intervene before incidents occur, bringing a more proactive approach to occupational safety and health (OSH). In high-risk or physically demanding environments, tools such as wearables, artificial intelligence (AI)-powered systems are transforming how risks are identified and addressed. Their success lies in combining technical innovation with collaboration between developers and end-users, worker participation and transparent use of data and algorithms, among others. The case studies presented in this news article showcase practical examples of smart digital systems in action in the EU and beyond, highlighting how they are being applied to address specific risks, improve working conditions and support more effective OSH management.

Wearables for ergonomics
Posture-monitoring wearables developed by an international OSH innovation company track workers’ movements in real time to help prevent musculoskeletal disorders (MSDs). High-risk behaviours such as excessive bending, poor lifting techniques or repetitive shoulder and back movements are identified, prompting individual alerts in real time that encourage safer movement patterns. Data from these devices can also inform ergonomic improvements to workstations and be used to improve safety training through an app. The technology is well suited to physically demanding sectors like logistics, construction and manufacturing. However, lack of trust in the systems, privacy breaches or technical problems such as malfunctions, false alarms or discomfort could create additional risks for OSH.

Armband for real-time data analysis
A smart armband used by a small software company from the United States collects both biometric and environmental data to monitor workers’ physical state in real time. Indicators such as heat, lighting and noise levels, as well as repetitive movements and physical efforts are tracked continuously to help identify stress or physical strain. Alerts are triggered when certain thresholds are met, allowing for timely intervention. These armbands are particularly beneficial in physically intense or thermally challenging work environments, but there is a risk of information overload for safety professionals and the danger of a false sense of protection, all of which require strong data protection policies, transparent communication and training.

Sensors for gas infrastructure worksites
Portable gas sensors developed by a German manufacturer in the fields of medical and safety technology are used to improve risk detection in environments where gas exposure may happen, such as energy or petrochemical sites, since gases can be odourless, tasteless and invisible. Multi-gas detection systems feed real-time data to a central platform where exposure levels are remotely monitored. These tools enhance emergency preparedness and reduce the chance of undetected gas leaks or accumulations, but employers and workers need to be aware of potential accuracy issues caused by environmental conditions or poor maintenance, as well as the risks of false alarms and overreliance on the device at the expense of other safety measures.

Headband for fatigue risk monitoring
Wearable headbands equipped with electroencephalogram (EEG) sensors are being used to detect signs of reduced alertness or mental fatigue in real time, in this case within an international mining company. These devices, used exclusively for safety-critical functions and requiring strong worker involvement, alert workers or supervisors when attention levels drop, thereby preventing fatigue-related accidents in high-risk environments. They are particularly useful in roles involving shift work, long hours or repetitive tasks. Although the technology can support better fatigue management and more adaptive scheduling, it may also have a negative impact on workers’ psychosocial health if they feel monitored or surveilled based on their cognitive performance or mental state. Consequently, privacy considerations and worker consultation are essential.

Smart insoles for lone worker protection
Smart insoles employed by a French company provide additional safety support for workers in isolated or remote locations by monitoring motion patterns to detect incidents such as falls or immobility. When a potential accident occurs and no response is received, an alert is sent with the worker’s GPS location to designated contacts. The insoles can also receive vibration-based instructions, which can be used in emergencies such as evacuation procedures. This solution is particularly useful in construction, utilities and field maintenance roles where workers may operate alone. These devices expand protection to otherwise hard-to-reach workers, yet, in remote areas, connectivity problems could delay response. Moreover, there is a risk of employers using the insoles as a substitute for human presence of coworkers or teams, ultimately creating additional challenges.

Wearables for remote OSH assessments
Wearable headsets used by a German multinational technology company equipped with cameras and microphones are enabling safety professionals to conduct remote audits and inspections. These devices, smart or extended reality glasses, transmit live video and audio from the worksite to off-site OSH experts, allowing them to assess safety conditions without needing to be physically present. The approach improves flexibility and response time and is especially effective for decentralised operations or situations with restricted access. However, some workers may feel uneasy about being recorded, and the system’s reliance on continuous internet connectivity may limit its ability to capture the full context of on-site conditions.

Computer vision for unsafe event recognition
Computer vision systems developed by an Ireland-based manufacturer are capable of detecting unsafe behaviours or hazardous situations automatically with the help of artificial intelligence. Examples include identifying missing personal protective equipment (PPE), detecting entry into restricted areas or recognising unsafe proximity to machinery. Real-time alerts enable quicker intervention, and footage can be used later for training or incident analysis. However, for these systems to be effective, workers must trust them, which requires avoiding issues such as excessive screen time, cognitive overload and inadequate training.

Wearables to prevent hand-arm vibration syndrome
A type of wristwatch designed by a United Kingdom-based developer in OSH technology is helping reduce the risk of long-term injury from exposure to vibrations caused by power tools, particularly hand-arm vibration syndrome (HAVS). These wearables measure vibration levels in real time through sensors and alert workers when exposure is near unsafe limits, allowing for more accurate planning of tool use, breaks or rotation. The technology is particularly relevant in industries like construction, mining and manufacturing. Used correctly, these devices help workers actively manage their own exposure and avoid injuries, but without proper training, staff may over-rely on the technology. Moreover, there are concerns on the privacy and data security of the devices, as well as hygiene risks if the equipment is dirty or not properly cleaned.

As a general conclusion for all case studies, the principles for safe and healthy design of smart digital systems call for approaches that genuinely improve OSH, are developed in cooperation with deployers and workers, have a clear and transparent purpose and use, protect data security and privacy, and remain reliable in practice. They should also be compatible with existing systems, adaptable to specific contexts, easy for workers to use and capable of growing as needs evolve.

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