IVECO Valladolid

A very distinct safety culture can be found in the IVECO Valladolid plant. Since 2007, for example, a Safety Management Audit Training (SMAT) has been carried out by team leaders for all employees. Should “Unsafe Conditions” or “Unsafe Acts” be detected in an area, a consequent analysis and a follow-up training take place. Resulting from this, a disclosure of the root cause (e.g. lack of competence and knowledge, missing attention from Management, and an active inclusion of employees in the improvement process, attitude or behavioral shortfalls). The SMAT data have been analyzed with a software solution for a long time and measures are taken adequately. With the Virtual Reality Point, as one of the first plants of the group, Valladolid has introduced proactive digital safety training. Therefore, it is to no surprise that the Valladolid plant is a benchmark for safety in the IVECO Group.

A critical area from the perspective of safety is the discharge hall. Here, cargo validation, forklift truck traffic and truck discharge take place simultaneously. Because of the direct interaction between staff and machinery in the same hall, potential risk scenarios emerge, especially as many people come here from outside (drivers) and are therefore less trained. Despite the existence of safety protocols and mechanisms, because of the intensity and the complexity of the processes in this area (e.g. an average of 48 arriving vehicles per hour) an AI supported solution to support the existing safety measures has been implemented with the “Unsafe Acts Automatic Detection”.

The core of the submitted digital use case is the introduction of an intelligent solution for the real-time detection of safety-critical situations in industrial working environments. Using advanced image processing and artificial intelligence, the system automatically identifies risks and unsafe actions by people, vehicles or forklift trucks in a defined working environment. If necessary, acoustic warnings are issued immediately via the existing system and potentially endangered persons are warned preventively.

All SMAT (Safety Management Audit Training) data is collected in a software tool to record safety-relevant data. In addition, the latest technologies are used for support:

• 180° and 90° camera systems for multi-dimensional visual monitoring
• Virtual reality modules for proactive, advanced safety training
• Tablets and GPS in forklift trucks with visual driving support
• Neural BI app for visualization, analysis and control of safety-relevant information in real time

The results of all monitoring systems are constantly updated and allow continuous 24/7 real-time monitoring. Real-time alerts can be configured individually for individual zones. Historical data analyses enable not only the derivation of trends, but also precise forecasts. The KPIs can be called up at any time in table or graphic format and exported to Microsoft Excel with a single click.

The system uses configurable electric, acoustic and verbal alert messages. Communication is targeted on the basis of current data and customized security strategies.

All image data is stored in encrypted form and is subject to the strictest data protection guidelines at national and European level. Personal image content is automatically made unrecognizable to ensure the anonymity of all employees.

For this outstanding achievement in the digitalization of safety-critical situations in industrial working environments and the successful integration into proven management processes, the IVECO Valladolid plant receives the prestigious Automotive Lean Production Award 2025 in the Digital Use Case category. Congratulations!

The plant Valladolid specializes on the production of lightweight commercial vehicle transporters (IVECO Daily) and components for heavy commercial vehicles. Around 130 Chassis (cab-models) and Daily Hi-Matic-Variants with 8-gear-automatic are manufactured there daily. Today, the Daily is in operation in over 110 countries, while 80% of production is exported to Europe, Africa and the Middle East. Alongside the manufacturing of the Daily, Valladolid plays a crucial role in the production of driver cabins for heavy commercial vehicles. In this area, driver cabins are manufactured for models like the S-WAY and Trakker and delivered to Madrid in painted condition.