ErgoGuard — Continuous Ergonomic Risk Assessment with AI
Real-time REBA scoring from any IP camera. Detect awkward postures the moment they happen, prevent cumulative injuries, and protect your workforce — without manual observation or dedicated ergonomics specialists.
What ErgoGuard does
Manual ergonomic risk assessments are costly, infrequent, and miss most of what actually happens on the floor. ErgoGuard runs continuously on existing IP-camera footage, computes REBA (Rapid Entire Body Assessment) scores for every worker on every shift, and surfaces the highest-risk postures before they become injuries.
Key capabilities
- Three-stage AI pipeline — person detection & tracking (YOLOv8) → 17-keypoint pose estimation (YOLO11x-Pose) → back-support-belt classification
- Per-worker, per-frame REBA scoring on the 1–15 scale, mapped to 5 risk levels (Negligible → Very High)
- Joint-angle calculations — trunk flexion / lateral tilt / twist, neck angle, upper arm, lower arm, wrist, knee bend, per side
- Activity classification — automatic recognition of overhead reaching, lifting, and idle states
- Back-belt compliance tracking — per worker, per shift
- Trend analytics — shift-level summaries, per-worker risk profiles, historical comparisons
- ROI dashboards — Ergonomic Intervention ROI cards, predictive injury analytics
How it works
ErgoGuard processes video frames from existing RTSP IP cameras (no special hardware). Stage 1 detects and tracks workers, maintaining consistent IDs across frames. Stage 2 estimates 17 COCO keypoints to compute joint angles. Stage 3 classifies whether each worker is wearing a back-support belt. Joint angles feed REBA Group A (trunk, neck, legs) and Group B (arms, wrists), producing a combined total score and a risk-level mapping. All measurements are stored in the ergo_posture_events table for trend analysis and reporting.
Where it pays off
- Warehouse picking and distribution centers
- Manufacturing assembly and packaging lines
- Logistics and material-handling operations
- Food processing and pharmaceutical production
- Any operation with repetitive reaching, lifting, or sustained awkward postures
Deployed in 5 days
Like every Braingine product, ErgoGuard is delivered on the 5-Day Implementation framework — live ergonomic monitoring in a working week, not a six-month integration project. It works on cameras you already have, integrates with the dashboards you already use, and starts producing risk scores from day one.