Procedures such as lockout-tagout (LOTO) have been a cornerstone of electrical safety for decades
In factories across the world, some of the most dangerous threats remain unseen. Live electrical leakage and arc-flash incidents continue to injure thousands each year despite decades of safety protocols. In 2021–22 alone, the US Bureau of Labor Statistics recorded 3,260 non-fatal electrical injuries, with arc-flash-type incidents accounting for up to a fifth of cases. For those affected, the consequences can be life-altering — severe burns, loss of mobility, or, in the worst cases, death after prolonged recovery.
“These are more than statistics,” says Kausthub Kaundinya, CEO and Co-Founder of Jarsh Safety. “They are people — real workers — whose lives have been permanently altered. Safety equipment has to go beyond compliance and become an intelligent partner in preventing such incidents.”
Limits of traditional safety
Procedures such as lockout-tagout (LOTO) have been a cornerstone of electrical safety for decades. Yet compliance remains worryingly low: just 29 per cent of workplaces meet full LOTO standards. The result is stark — 80% of electrical incidents stem from LOTO failures, and three-quarters of electrical fatalities occur among non-electrical workers. Compounding this are ageing systems and poor equipment design, which can place even those far from control panels in harm’s way.
Smart PPE: from passive protection to predictive action
A new wave of personal protective equipment (PPE) is emerging — no longer just passive gear, but intelligent, connected systems capable of predicting hazards before they strike. Jarsh Safety is among the leaders in this shift. Its SmartVolt device detects live voltage without contact, the Kavach Harness monitors safety anchoring and fall events, and WorkAlive enables live video oversight from remote supervisors.
“We are not here to sell gadgets,” says Kaundinya. “Our goal is to create wearables that sense, communicate, and act — whether that’s detecting a live hazard before contact or allowing supervisors to intervene remotely. PPE must become the first line of industrial intelligence.”
This movement reflects a broader market trend. The earth-leakage protection systems sector, valued at USD 670m in 2024, is forecast to exceed USD 980m by 2033. Just as residual current circuit breakers (RCCBs) can disconnect circuits automatically, integrated smart PPE is designed to detect and respond to danger faster than human reflexes allow.
Real-time data & predictive monitoring
IoT-enabled PPE is now being linked to centralised monitoring dashboards, where machine-learning algorithms detect abnormal heat spikes, insulation breakdowns, or precursors to an arc-flash. In battery assembly lines, deep-learning models are being tested to predict and prevent thermal runaway.
A 2024 Fluke survey found that 78 per cent of industrial workers rely on tool-based safety measures — and increasingly expect connected systems to be part of their protection.
From compliance to culture of prevention
The real transformation lies not only in the gear itself, but in how workplaces approach safety. Hazard control is moving from reactive measures to proactive alerts, giving non-electrical staff early warnings before a threat escalates. Embedded intelligence complements human decision-making, enabling faster and more informed responses.
Intelligent monitoring in high-risk industries
In oil refineries, thermal power plants, and heavy manufacturing facilities, hazards can escalate in seconds. While smart helmets, jackets, and gloves improve individual protection, their impact grows significantly when combined with 24/7 monitoring. Systems that track PPE usage in real time — from helmets and goggles to gloves and safety shoes — help safety teams pinpoint recurring violations, identify high-risk areas, and recognise patterns that might otherwise go unnoticed.
Vehant Technologies has implemented such solutions at sites including Chennai Petroleum Corporation Limited and Maithon Power Plant, where recurring safety lapses demanded urgent action.
“Safety equipment and training are no longer enough,” says Kapil Bardeja, Co-Founder and CEO of Vehant Technologies**. “We need a technology-driven safety culture where detection, data, and decisions work together before an incident can escalate.”
“Real-time monitoring, when combined with smart gear, gives managers the ability to see not just what went wrong, but where and why it keeps happening,” he adds. “That insight can save lives, improve safety, and boost productivity.”
Future of hazard control
For both Jarsh Safety and Vehant Technologies, the mission is to embed intelligence into the very fabric of workplace safety. By combining connected PPE with predictive analytics and intelligent monitoring, factories can significantly reduce risk while improving efficiency.