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Employee Safety Monitoring: The technology behind a safer workplace

Stop guessing, start protecting. We engineer custom safety monitoring solutions that provide real-time visibility, automated alerts, and proactive risk management, transforming your workplace into a strategic safety asset.
needCode IoT

We work with Industry Leaders

The challenges of an unsafe workplace

In industrial and manufacturing sectors, worker safety is not just a compliance issue, it’s a direct operational and financial liability. We have identified core challenges that compromise workplace safety.

Limited visibility

Without real-time data, safety managers struggle to monitor worker location and activity, especially in large facilities with hazardous zones. This lack of visibility can lead to delayed responses in emergencies and non-compliance with safety regulations.

Accident risks

The lack of automated proximity warnings and fall detection increases the risk of accidents. This can result in workplace injuries, regulatory fines, and legal liabilities.

Operational inefficiencies

Manual safety checks and reporting are time-consuming and unreliable. A lack of real-time data on worker location and proximity to machinery can lead to suboptimal workflows and increased risk of accidents.

Integration complexity

Connecting a diverse range of safety systems, from access control to emergency response, into a single, unified platform is a major technical hurdle.

Our solutions for a smarter workplace

Our expertise in employee safety monitoring goes beyond standard solutions. We deliver a complete, modular ecosystem that connects hardware, software, and analytics into a cohesive, purpose-built system.

01

Data acquisition and protocol translation

Custom UWB tags & beacons

We engineer custom UWB tags and beacons for your specific application. Our Hybrid Safety Tags can be miniaturized for wearables or ruggedized for industrial environments, ensuring durability and perfect fit.

Advanced RTLS positioning

We use Ultra-wideband (UWB) technology to achieve precision down to sub-30 centimeters. This level of accuracy is critical for ensuring worker safety in hazardous zones and for collision avoidance.

Multi-protocol support

Our gateways are engineered to support a mix of wired (CAN, Modbus) and wireless (LTE, UWB, BLE) protocols. Our Protocol Translation Gateway converts these diverse data streams into a unified format, enabling a single platform for all your safety assets.

02

Intelligence and action

Multi-source event correlation

Our Multi-Source Event Correlation Engine transforms raw location data into intelligent events and insights. It combines UWB's precise position with data from other sensors (e.g., IMUs, temperature) to detect complex scenarios, such as a worker entering a hazardous zone while carrying a specific piece of equipment.

Automated workflows

Our systems enable precise, automated actions based on location data. We can implement Local Automation Rules Engines that trigger events—such as shutting down a machine when a worker enters its zone—without relying on the cloud, ensuring instant, low-latency responses.

Fall & inactivity detection

Our Hybrid Safety Tags are equipped with onboard accelerometers and gyroscopes, which enable sensor fusion for accurate fall detection and motion analysis. This allows the system to send instant alerts if a worker falls or becomes inactive, ensuring a rapid response in case of emergency.

03

Analytics and operational intelligence

Data analytics & insights framework

We turn continuous streams of safety data into actionable intelligence. Our Data Analytics & Insights Framework supports real-time analysis and historical trend exploration, enabling you to optimize safety protocols, identify high-risk zones, and forecast maintenance needs.

Unified API layer

Our API Gateway & Integration Layer acts as a centralized access point for all safety data. This simplifies integration with your existing safety management software, dispatch systems, and HR platforms, ensuring a seamless flow of information.

Resilience and compliance

We design UWB anchors and tags with inherent resilience, including support for PoE (Power over Ethernet) for simplified deployment. Our solutions also meet stringent safety and security standards, including ATEX/IECEx compliance for hazardous environments and cryptographic authentication between tags and anchors.

What a smarter safety solution means for your business

Our employee safety monitoring solutions are engineered to deliver a clear and measurable return on investment, transforming operational challenges into strategic advantages.

Enhanced safety & compliance

Reduce accident rates by implementing automated safety alerts and geofencing. Our systems help you adhere to strict regulatory standards and improve overall workplace safety.

Boosted operational efficiency

Reduce delays and optimize workflows by gaining real-time visibility into worker location and activity. Our solutions help you identify high-risk areas and streamline operational processes.

Reduced insurance costs

Demonstrate a proactive commitment to safety with a data-driven approach to risk management, which can lead to reduced insurance premiums and legal liabilities.

Maximized asset utilization

Use real-time location data to ensure workers are always in the right place at the right time, reducing idle time and optimizing resource allocation.

What we bring to the project

At needCode, we build complete safety ecosystems. Our modular partnership model allows us to engage at any stage of your project, ensuring a seamless and low-risk path to a safer workplace.

01

Defining your safety blueprint

We begin by translating your safety goals into a clear, technical roadmap.
  • Feasibility analysis
    We conduct a deep dive into your operational environment, from hazardous zones to existing machinery, to define the optimal technology stack for your specific safety challenges. We can determine whether UWB, BLE, or a multi-protocol approach is the right fit.
  • Prototyping & validation
    We utilize our library of proven building blocks to rapidly design and prototype a working proof of concept (PoC). This allows us to validate your safety solution's core functionality in a controlled environment, minimizing upfront risk and accelerating the path to an MVP.
  • Strategic roadmap
    Our team works with you to create a comprehensive IoT Strategic Roadmap, a detailed plan that outlines the development, integration, and deployment of your safety monitoring system from initial concept to full-scale rollout.

02

Building your custom safety solution

We deliver a complete solution tailored to your needs, whether it's a single component or a full, end-to-end system.
  • Hardware development
    We can design and engineer custom Hybrid Safety Tags and UWB Anchors that are ruggedized for industrial environments, or miniaturized for wearables. We ensure our hardware is not only robust but also perfectly suited to your specific use case.
  • Software intelligence
    We build the core software that powers your safety ecosystem. This includes the Multi-Source Event Correlation Engine for complex event detection and the Local Automation Rules Engine for instant, on-device responses, ensuring that your system is both smart and resilient.
  • Unified integration
    We develop the necessary API gateways and integration layers to seamlessly connect your new safety platform with your existing enterprise systems—such as safety management software, emergency response systems, and HR platforms.

03

Deployment and continuous optimization

Our support extends beyond the product launch. We provide the tools and expertise to ensure your solution remains secure, reliable, and continuously optimized.
  • Operational support
    We provide a full suite of tools for remote diagnostics, field support, and secure OTA (Over-the-Air) updates, ensuring that your system remains up-to-date and reliable.
  • Data for continuous improvement
    We empower you to use the gathered safety data to continuously optimize safety protocols, identify high-risk areas, and improve overall operational efficiency.

Where our safety solutions fit

Our modular approach allows us to deliver optimized solutions across multiple industrial applications, solving common problems with uncommon speed and precision.

Industrial & manufacturing

  • Proximity warnings & collision avoidance
    Implement secure geofencing boundaries with UWB, providing proximity warnings for collision avoidance with machinery and vehicles. Our solutions can automatically slow down or stop a machine if a worker enters a dangerous zone.
  • Fall & inactivity detection
    Use our Hybrid Safety Tags to automatically detect if a worker has fallen or been inactive for a prolonged period. The system can then send an instant alert to supervisors, ensuring a rapid response in an emergency.
  • Geofencing for safety compliance
    Track worker location in real-time to ensure compliance with safety regulations. Our solutions can automatically log who entered a restricted area and for how long, providing data for automated compliance reporting.

Mining & heavy industry

  • Real-time worker location
    Track the location of workers and vehicles in hazardous zones, ensuring on-site safety and rapid response in emergencies. Our solutions provide a complete, real-time map of your operational environment.
  • Automated safety alerts
    Our systems can send automated alerts to workers and supervisors if a vehicle is approaching a dangerous area or if a worker is in a high-risk zone.
  • Emergency response optimization
    In case of an emergency, our systems can provide a real-time map of worker locations, helping emergency responders to quickly and efficiently locate and assist those in need.

Construction & transport

  • On-site safety
    Monitor worker proximity to heavy machinery and vehicles, preventing accidents and ensuring compliance with safety regulations. Our solutions can be used to track workers on foot and vehicles in a single, unified system.
  • Tool & equipment tracking
    Our solutions can be used to track tools and equipment on large construction sites, reducing the risk of theft and ensuring that all necessary equipment is available when needed.
  • Real-time monitoring
    Our systems provide a continuous stream of data on worker location and activity, enabling managers to optimize workflows and ensure that all safety protocols are being followed.

Healthcare & life sciences

  • Staff safety
    Use staff proximity badges to manage access control in sensitive areas and track personnel flow for compliance and safety. Our solutions can log who entered a restricted lab and for how long, providing data for automated compliance reporting.
  • Patient safety
    Monitor patient movement within wards to enhance safety and improve response times. Our systems can be used to track patients at risk of falling or wandering, providing an early warning system for caregivers.
  • Emergency response
    In a hospital setting, our solutions can provide a real-time map of staff and patient locations, helping emergency responders to quickly and efficiently locate and assist those in need.

Case studies

Read more in our E-books

Testimonials

“I think the key takeaway from needCode is their ability to adapt and understand the customer's requirements. That took away probably a large portion of what could have been a lot of development time and expense for both companies.”
Bob Folkestad
Bob Folkestad
President at Creative Werks
“One aspect that truly sets needCode apart is its profound expertise in firmware development. Their proficiency in various programming languages, embedded systems and hardware architecture is truly impressive. When faced with difficult problems, their strong problem-solving skills and analytical mindset shine through, allowing them to overcome obstacles with remarkable ease.”
avatar Semeh Sarhan
Semeh Sarhan
CEO at Xtrava
“I worked with needCode while leading the NWTN-Berlin team in 2018. A big chunk for our FW development has been outsourced to them and they had proven to iterate very quickly, following specs and deliver on time. It was great working with them. I recommend working with needCode’s team on any Embedded SW development.”
avatar Marco Salvioli Mariani
Marco Salvioli Mariani
CTO at NWTN Berlin GmbH
“needCode Team proved to be one of the best engineers I have ever met. The part I like the most about the team is the more difficult an obstacle seems to be, the more motivated they were to find a solution and a way forward.”
A Testimonial picture
Szymon Słupnik
CTO at Silvair
“needCode is an outstanding partner. Their quick follow-up, scalability, and extensive professional network set them apart. Their expertise in wireless technologies has been valuable, supporting us from low-level drivers to architecture discussions.”
avatar Tim Allemeersch
Tim Allemeersch
Director at Qorvo, Inc.
“needCode did a great job improving the firmware of the Vai Kai connected toys and developing new features, surpassing our expectations multiple times. I would definitely recommend hiring Bartek and needCode for the embedded software projects!”
avatar Matas Petrikas
Matas Petrikas
CEO & Co-founder
at Vai Kai UG

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Bartek Kling
Bartek Kling / CEO
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Manufacturing

Modern manufacturing machines are typically equipped with IoT sensors that capture performance data. AIoT technology analyzes this sensor data, and based on vibration patterns, the AI predicts the machine's behavior and recommends actions to maintain optimal performance. This approach is highly effective for predictive maintenance, promoting safer working environments, continuous operation, longer equipment lifespan, and less downtime. Additionally, AIoT enhances quality control on production lines.

For example, Sentinel, a monitoring system used in pharmaceutical production by IMA Pharma, employs AI to evaluate sensor data along the production line. The AI detects and improves underperforming components, ensuring efficient machine operation and maintaining high standards in drug manufacturing.

Logistics & supply chain

IoT devices - from fleet vehicles and autonomous warehouse robots to scanners and beacons - generate large amounts of data in this industry. When combined with AI, this data can be leveraged for tracking, analytics, predictive maintenance, autonomous driving, and more, offering greater visibility into logistics operations and enhancing vendor partnerships.

Example: Amazon employs over 750,000 autonomous mobile robots to assist warehouse staff with heavy lifting, delivery, and package handling tasks. Other examples include AI-powered IoT devices such as cameras, RFID sensors, and beacons that help monitor goods' movement and track products within warehouses and during transportation. AI algorithms can also estimate arrival times and forecast delays by analyzing traffic conditions.

Retail

IoT sensors monitor movement and customer flow within a building, while AI algorithms analyze this data to offer insights into traffic patterns and product preferences. This information enhances understanding of customer behavior, helps prevent stockouts, and improves customer analytics to drive sales. Furthermore, AIoT enables retailers to deliver personalized shopping experiences by leveraging geographical data and individual shopping preferences.

For instance, IoT sensors track movement and customer flow, and AI algorithms process this information to reveal insights into traffic patterns and product preferences. This ultimately leads to better customer understanding, stockout prevention, and enhanced sales analytics.

Agriculture

Recent research by Continental reveals that over 27% of surveyed farmers utilize drones for aerial land analysis. These devices capture images of crops as they are and transmit them to a dashboard for further assessment. However, AI can enhance this process even further.

For example, AIoT-powered drones can photograph crops at various growth stages, assess plant health, detect diseases, and recommend optimal harvesting strategies to maximize yield. Additionally, these drones can be employed for targeted crop treatments, irrigation monitoring and management, soil health analysis, and more.

Smart Cities

Smart cities represent another domain where AIoT applications can enhance citizens' well-being, facilitate urban infrastructure planning, and guide future city development. In addition to traffic management, IoT devices equipped with AI can monitor energy consumption patterns, forecast demand fluctuations, and dynamically optimize energy distribution. AI-powered surveillance cameras and sensors can identify suspicious activities, monitor crowd density, and alert authorities to potential security threats in real-time, improving public safety and security.

For example, an AIoT solution has been implemented in Barcelona to manage water and energy sustainably. The city has installed IoT sensors across its water supply system to gather water pressure, flow rate, and quality data. AI algorithms analyze this information to identify leaks and optimize water usage. Similarly, smart grids have been introduced to leverage AI to predict demand and distribute energy efficiently, minimizing waste and emissions. As a result, these initiatives have enabled the city to reduce water waste by 25%, increase renewable energy usage by 17%, and lower greenhouse gas emissions by 19%.

Healthcare

Integrating AI and IoT in healthcare enables hospitals to deliver remote patient care more efficiently while reducing the burden on facilities. Additionally, AI can be used in clinical trials to preprocess data collected from sensors across extensive target and control groups.

For example, intelligent wearable technologies enable doctors to monitor patients remotely. In real-time, sensors collect vital signs such as heart rate, blood pressure, and glucose levels. AI algorithms then analyze this data, assisting doctors in detecting issues early, developing personalized treatment plans, and enhancing patient outcomes.

Smart Homes

The smart home ecosystem encompasses smart thermostats, locks, security cameras, energy management systems, heating, lighting, and entertainment systems. AI algorithms analyze data from these devices to deliver context-specific recommendations tailored to each user. This enables homeowners to use utilities more efficiently, create a personalized living space, and achieve sustainability goals.

For example, LifeSmart offers a comprehensive suite of AI-powered IoT tools for smart homes, connecting new and existing intelligent appliances and allowing customers to manage them via their smartphones. Additionally, they provide an AI builder framework for deploying AI on smart devices, edge gateways, and the cloud, enabling AI algorithms to process data and user behavior autonomously.

Maintenance (Post-Release Support)

When your product is successfully launched and available on the market we provide ongoing support and maintenance services to ensure your product remains competitive and reliable. This includes prompt resolution of any reported issues through bug fixes and updates.

We continuously enhance product features based on user feedback and market insights, optimizing performance and user experience.

Our team monitors product performance metrics to identify areas for improvement and proactively addresses potential issues. This phase aims to sustain product competitiveness, ensure customer satisfaction, and support long-term success in the market.

Commercialization (From MVP to Product

Our software team focuses on completing the full product feature range, enhancing the user interface and experience, and handling all corner cases. We prepare product software across the whole lifecycle by providing all necessary procedures, such as manufacturing support and firmware upgrade.

We also finalize the product's hardware design to ensure robustness, scalability and cost-effectiveness.

This includes rigorous testing procedures to validate product performance, reliability, and security. We manage all necessary certifications and regulatory compliance requirements to ensure the product meets industry standards and legal obligations.

By the end of this phase, your product is fully prepared for mass production and commercial deployment, with all documentation and certifications in place.

Prototyping (From POC to MVP)

Our development team focuses on implementing core product features and use cases to create a functional Minimum Viable Product (MVP). We advance to refining the hardware design, moving from initial concepts to detailed PCB design allowing us to assemble first prototypes. Updated documentation from the Design phase ensures alignment with current project status. A basic test framework is established to conduct preliminary validation tests.

This prepares the product for real-world demonstrations to stakeholders, customers, and potential investors.

This phase is critical for validating market readiness and functionality before proceeding to full-scale production.

Design (From Idea to POC)

We meticulously select the optimal technology stack and hardware components based on your smart product idea with detailed use cases and feature requirements (Market Requirements Document / Business Requirements Document). Our team conducts thorough assessments of costs, performance metrics, power consumption, and resource requirements.

Deliverables include a comprehensive Product Requirements Document (PRD), detailed Software Architecture plans, an Initial Test Plan outlining validation strategies, Regulatory Compliance Analysis to ensure adherence to relevant standards, and a Proof of Concept (POC) prototype implemented on breakout boards.

This phase aims to validate the technical feasibility of your concept and establish a solid foundation for further development.

If you lack a validated idea and MRD/BRD, consider utilizing our IoT Strategic Roadmap service to gain insights into target markets, user needs, and desired functionality. Having a structured plan in the form of an IoT Strategic Roadmap before development begins is crucial to mitigate complications in subsequent product development phases.