Investigating an Engineering
Project
Almutaz Alkharusi
1787
8B
Contents
Introduction to the assignment ................................................................................... 4
Introduction to the problem ......................................................................................... 4
Initial Requirements.................................................................................................... 5
Existing Products ....................................................................................................... 5
Product 1 (Danger Zone Detection) ........................................................................ 5
Product 2 (PPE Detection) ...................................................................................... 5
Research .................................................................................................................... 6
Materials ................................................................................................................. 6
Aluminium ........................................................................................................... 6
Carbon Steel ....................................................................................................... 6
Oak Wood ........................................................................................................... 6
Plywood .............................................................................................................. 6
Polycarbonate ..................................................................................................... 7
Manufacturing Processes ....................................................................................... 7
Sand Casting....................................................................................................... 7
Injunction Moulding ............................................................................................. 7
Solutions .................................................................................................................... 8
First Solution ........................................................................................................... 8
Second Solution...................................................................................................... 8
Third Solution ......................................................................................................... 8
Feasibility ................................................................................................................... 9
Solution 1 Feasibility ............................................................................................... 9
Solution 2 Feasibility ............................................................................................... 9
Solution 3 Feasibility ............................................................................................... 9
Comparison .............................................................................................................. 10
Potential size and complexity ............................................................................... 10
Potential size of benefits ....................................................................................... 10
Cost and time ....................................................................................................... 10
Specialist expertise ............................................................................................... 11
Risks ..................................................................................................................... 11
Sustainability issues ............................................................................................. 11
Legal constraints................................................................................................... 11
Choice and Justifications.......................................................................................... 12
References ............................................................................................................... 13
Introduction to the assignment
In this assignment, an engineering problem will be explained, then 3 solutions will be
introduced and explained in detail, and the preferred solution will be chosen for further
development
Introduction to the problem
Workshops are designed to be spaces of creation and innovation, but at the same
time, they are filled with hazards ranging from High-speed rotating blades, pressure-
based systems, flammable chemicals, heavy machinery, and sharp tools. To manage
these risks, workshops heavily rely on strict safety rules and operational protocols.
Yet, in many educational and industrial places, these rules are frequently ignored or
broken. Breaking rules in workshops might not seem like a big deal, such as not
wearing safety goggles, skipping the machine checks, or leaving tools on the floor. But
these small violations can lead to bigger consequences, ranging from small cuts to
serious injuries to permanent disability or even death.
Consequences: Rule-breaking in workshops comes in
many forms, such as not wearing Personal Protective
Equipment, removing guards from saws and lathes while
working, leaving liquids on the ground, using damaged
tools, and running or fighting. Breaking these rules can
cause a variety of injuries, such as deep cuts or even lost
fingers from saws and rotating tools. Crush injuries to Figure 1(Workshop Safety Rules)
hands or feet from heavy machines. Skin burns from hot
metal, welding sparks, or spilled chemicals. Eye damage from flying debris or liquid
splashes. Breathing problems or long-term lung illness from dust, fumes, and poor
ventilation. Gradual hearing loss from loud machinery. Repeating the same
movements or working in awkward positions can cause tired, sore muscles, joint pain,
and long-term pain.
Respond, their impact, and how to prevent them in the future: Immediate
responses to these incidents start with providing first aid and calling emergency
services for injured workers. Evacuating the area to prevent further harm and stop all
related processes. Followed by notifying supervisors and management immediately,
securing all physical and digital evidence, and documenting the scene to support the
investigation. It can impact the operation by delaying production. And legal lawsuits
because of harmed workers, destroying the organization's reputation and trust from
their clients and the public. All these problems can lead to heavy financial losses and
reduced income. Short-term fixes for these problems often involve repairing machine
guards, replacing PPE, and retraining or firing those who were involved. Long-term
strategies to fix them start by addressing the roots of the problem: redesigning
equipment and processes to eliminate hazards, implementing new training and
supervision methods.
Initial Requirements
This project is an integrated workshop safety system that prevents common hazards
by combining smoke detection, safe-distance monitoring, running detection, personal
protective equipment detection, and air quality monitoring into one design. Smoke
detection system provides early fire warnings, safe distance monitoring to provide a
safe space around active machines, running detection to identify and alert when
people run in high risk areas, personal protective equipment detection to verify use of
required equipment such as eye, hand, and hearing protection, and air quality
monitoring to detect dust, fumes, and harmful gases and trigger ventilation or alarms.
Existing Products
Product 1 (Danger Zone Detection)
Danger zone detection creates configurable exclusion areas around machines and
work processes, then watches those areas continuously and immediately responds
when people enter them. It works by using cameras or sensors that have a built-in AI
module that scans a certain area looking for dangers and threats to workers, such as
exceeding the safe area allowed between the worker and the machine. [1]
Product 2 (PPE Detection)
PPE detection verifies that the required protective equipment is present and worn
correctly in high-risk areas. It uses cameras with AI vision modules that combine visual
and tag-based confirmation to increase certainty. The system continuously scans
workstations and access points for helmets, goggles, gloves, hi-vis vests, respirators,
and other items, issuing instant alerts to supervisors and managers when it detects
missing pieces. [2]
Research
Materials
Aluminium
Aluminium is a lightweight, ductile non-ferrous metal that is commonly used in
structural frames, housings, and components that benefit from low mass and good
corrosion resistance. Its advantages include a high strength-to-weight ratio, excellent
formability and extrudability, ease of use in CNC machining, and good thermal and
electrical conductivity, which can be anodized for further improvements in surface
durability and appearance. Disadvantages include lower stiffness and reduced fatigue
strength compared with steels and other materials, and reduced strength at high
temperatures. [3]
Carbon Steel
Carbon Steel is an iron-carbon alloy, its density is near 7.85 g/cm3, with a melting
range roughly between 1425–1540 °C its a ferrous material that is used in gears, car
shafts, and cutting tools. It has many advantages, such as its cost being low and can
be easily heat treated, its being widely available, and it being suitable for welding.
Disadvantages are its being weak against corrosion if not coated or plated, greater
mass compared with other non-ferrous materials, and it usually needs additional
surface finishing for appearance or environmental protection. [4]
Oak Wood
Oak wood is a type of hardwood that is mostly used in indoor and outdoor furniture,
alongside flooring. It is known for its high hardness, stiffness, wear resistance,
alongside its high durability and high density. Using it has many benefits, such as its
being water and weather resistant, alongside being resistant due to its tight grains.
However, it is considered expensive compared to softwoods, its weight is much higher
than other woods, needing more maintenance in exposed environments. [5]
Plywood
Plywood is a type of hardwoods that is made by pressing multiple layers of thin wood
veneers with their grain directions alternating, which helps resist warping and
shrinkage. Its widely used in construction and packaging due to its strength-to-weight
ratio. It’s widely used in construction and furniture due to its large sheet sizes, and
cost-effectiveness. Its main advantages include dimensional stability, good strength,
and ease of cutting. However, it has some drawbacks, such as having exposed edges
that are vulnerable to moisture, and lacks the natural beauty like the other solid woods.
[6]
Polycarbonate
Polycarbonate is a transparent thermoplastic used for machine guards, glazing, and
impact-resistant covers and safety equipment such as googles and face shields. it is
processed by injection moulding, thermoforming, or CNC machining, also it can be
finished by coating to improve scratch and UV resistance. It has many advantages
such as its High Impact resistance, good optical clarity making it an good alternative
for glass, ease of forming into more complex shapes. But, it has some disadvantages
such as its surface being weak to scratches if not hardened, its weak chemical
resistance, and its more expensive compared with other plastics such as ABS. [7]
Manufacturing Processes
Sand Casting
Sand casting is a widely used manufacturing process for producing large and complex
metal parts with good dimensional accuracy. It works by first creating a mold of the
desired part (typically made from wood, metal, or plastic), then it get placed inside a
container called a flask. Special casting sand is packed around the pattern to form a
mold, and if the part requires internal cavities, sand cores are inserted before
assembling the two halves of the mold. Once the mold is complete, molten metal such
as aluminum, steel, or iron is poured into the cavity through channels and left to cool
and solidify. After solidification, the sand mold is broken
apart to reveal the finished casting, which is then cleaned
and processed for final use. Advantages of sand casting
include its ability to produce large and intricate shapes,
compatibility with a wide range of metals, low tooling cost,
and flexibility for low or high production volumes. However,
it also has some disadvantages such as the rough surface
finish and lower dimensional accuracy compared to other Figure 2(Sand Casting)
casting methods. [8]
Injunction Moulding
Injection moulding is one of the most widely used manufacturing processes for
producing products made from thermoplastic materials. The process begins with the
mold getting designed and made from steel or aluminium using computer programs
and CNC machines. These machines help shape the mold and
add details like textures or logos. Once the mold is ready, plastic
pellets are poured into a hopper and heated until they melt. The
melted plastic is then pushed into the mold under high pressure
so it fills the shape quickly and evenly. After that, the mold is
closed and left to cool, which helps the plastic become solid and
strong. When it’s cooled down, the mold opens and the finished Figure 3(Injection Molding)
part comes out. If there’s any extra plastic around the edges, it
gets trimmed off to make the product smooth and clean. It has many advantages, such
as how fast it is, and the ability to make products in large quantities. Disadvantages
are that the molds are expensive to make and not ideal for small batches. [9]
Solutions
First Solution
First solution uses Arduino, Raspberry Pi, and an ultrasonic sensor, with a camera to
watch for PPE, check air quality, sense smoke, and detect if workers are in a safe area
from the machines. It works by placing the camera in the workshop and connecting it
to the Arduino board, while the board is connected to the Raspberry Pi server to check
if people wear PPE, the ultrasonic sensors map distances between the worker and
machines, air sensors read dust or gas levels, and smoke sensors trigger alarms, and
even detect if someone is running in the workshop. When one of these events occurs,
the system immediately sends an alert. Cons are that some components may be new
and tricky to deal with, and it needs steady power and a network.
Second Solution
The second solution is a mobile robot that patrols the workshop carrying a camera, a
smoke detector, and an air sensor to scan spaces and warn loudly if it finds a problem.
It functions by driving predefined routes, using the camera and sensors to inspect
hard-to-see areas, and using loudspeakers with lights to alert people while logging
incidents for review. Pros: it can identify and explain problems in a message form
because of the AI built in the board inside it, and it covers the whole workshop by
moving where fixed sensors can’t reach. Cons are that it’s slower to scan very large
areas, mobile smoke detection can delay alarms, and building a reliable navigation
system needs strong programming and robotics skills.
Third Solution
The third solution is a full advanced AI system combining ceiling smoke detectors,
accurate air sensors, multiple cameras, and PPE/person recognition to monitor
continuously. It works by collecting data from fixed ceiling detectors and distributed air
sensors with real-time video analysis to identify rule breakers and predict dangerous
conditions before they escalate, then notify supervisors. Pros: can enforce rules, give
early warnings, and provide high accuracy in air quality checks and behaviour
detection. Cons: it can be very expensive to design and install, and it's technically
complex to implement and maintain because AI systems are still a new Idea
Feasibility
Solution 1 Feasibility
Solution 1 uses Arduino, ultrasonic, Raspberry Pi, and cameras placed around the
workshop to detect PPE use, air quality, smoke, and running. They send alerts to the
supervisor when something’s wrong. Size and complexity can be considered as
medium; it covers specific zones and is scalable by adding more cameras and
sensors. The expected benefits are clear and local: faster detection of PPE violations,
earlier alerts for air-quality excursions and smoke, and quicker notification when
breaking other rules. This should reduce response times and lower the frequency of
minor incidents across monitored zones. Development cost and time are considered
medium; a working prototype can be assembled in weeks using simple parts, and the
full deployment for a small to medium workshop can be completed in two to three
months, with the main costs being sensors, cameras, boards, and power banks.
Solution 2 Feasibility
Solution 2 is a mobile robot that carries a camera, smoke detector, and air sensor and
patrols the workshop to scan for hazards, record evidence, and issue warnings when
it detects a problem. Size and complexity are considered to be medium to high due to
the difficulty in designing the robot to navigate between obstacles. The benefits
expected from the Robot are reaching areas that fixed sensors can't reach, providing
clear visual evidence, and giving voice alerts. Cost and time, time to develop a working
prototype might take up to 7 months, and parts costs can be expensive. Risks consist
of slow scanning of big areas, so delayed detection for some events, collisions with
workers or machines, and being damaged or stolen. Specialist skills required are
robotics, coding, embedded control, and mechanical maintenance. About
sustainability, it consumes higher energy, moving parts mean more maintenance, so it
works better in open and less cluttered workshops. Legal constraints: robots must
meet workplace safety rules, and alarms must follow local noise regulations.
Solution 3 Feasibility
Solution 3 is an advanced AI system with ceiling smoke detectors, many cameras,
accurate air sensors, and PPE/person recognition that fuses data to monitor the whole
site continuously and predict problems early. Size and complexity are considered
challenging because full site continuous monitoring with AI data storing is complex to
design. Expected benefits are having high accuracy, early warning, problem
prediction, and the ability to identify rule-breakers. Cost and time: it's expected to take
a very long time because coding, installation, and AI model training can take from 6 to
12 months with a big budget. Specialist skills required are AI model coding, data
engineering, systems integration, and a certification in safety. Risks consist of financial
and technical risks and privacy, and data-protection issues. Sustainability issues are,
large power footprint, may be overkill for small sites, but valuable for high-occupancy or
high-risk facilities—legal constraints: strict privacy rules for video analytics.
Comparison
Potential size and complexity
Solution 1 is medium-sized. It works well in workshops where sensors can be placed
in fixed zones. The system is not too complex, but combining different parts like
Arduino, Raspberry Pi, ultrasonic sensors, and cameras needs careful setup and
wiring.
Solution 2 is made for bigger areas. The robot can move around and reach places
that fixed sensors can’t. But the system is more complex because it needs mapping,
navigation, and obstacle avoidance. It also needs to work safely around people and
machines.
Solution 3 is designed for large and busy workshops. It uses many cameras, ceiling
detectors, and smart software to monitor everything at once. The system is very
complex because it mixes video, sensor data, and AI to make decisions in real time.
Potential size of benefits
Solution 1 has good benefits for small and medium workshops. It sends fast alerts
when something goes wrong, helps reduce small accidents, and improves safety in
specific zones.
Solution 2 gives better benefits because it can scan areas that fixed sensors miss. It
can explain problems clearly, record evidence, and give loud warnings. This helps
improve safety and awareness across the whole workshop.
Solution 3 gives the best benefits. It can catch rule-breakers, predict danger before it
happens, and give full reports. It improves safety across the whole site and helps
prevent serious incidents.
Cost and time
Solution 1 is the cheapest and fastest. a working version can be built in a few weeks,
and the full setup in a few months. The cost is low to medium, depending on how many
sensors are used.
Solution 2 requires more money and time. Building a robot with sensors, motors, and
navigation software takes several months. Careful testing is needed before it can be
used in the workshop.
Solution 3 is the most expensive and time consuming. It involves buying many
cameras and sensors, building the AI system, training models, and testing everything.
Development can take a year or more.
Specialist expertise
Solution 1 requires basic electronics and programming skills. It involves connecting
sensors, writing simple code, and installing the system. These skills are generally
easy to learn or find.
Solution 2 needs advanced expertise in robotics, programming, and mechanical
design. It requires people who can build robots, are good at coding, and can maintain
moving parts
Solution 3 demands expert knowledge in AI, computers, data handling, and system
design. Most of the work will require support from professionals or companies that
specialize in smart systems.
Risks
Solution 1 has small risks. Sensors may give incorrect readings, and power cuts can
stop the system. These issues are usually easy to fix.
Solution 2 comes with more risks. The robot might be slow, crash into objects, or
break down. It may miss fast problems if it’s not in the right place. Proper testing is
needed to avoid these issues.
Solution 3 carries big risks. The system may give false alerts, face privacy concerns,
or be difficult to maintain. It also needs regular updates to stay effective.
Sustainability issues
Solution 1 is sustainable. Each sensor uses little energy, and most parts are easy to
find in Oman. However, installing many sensors increases maintenance and battery
waste.
Solution 2 uses more energy and needs charging stations. Its moving parts require
frequent repairs. It works best in open workshops and may struggle in crowded
spaces. Some parts may be harder to source locally.
Solution 3 consumes a lot of power and includes many components that need
replacement. It is ideal for large workshops but too much for small ones. Planning
ahead is necessary to ensure parts are available and the system stays running.
Legal constraints
Solution 1 must follow privacy laws when using cameras. Smoke detectors and
alarms must meet safety standards in Oman.
Solution 2 must comply with safety regulations for moving robots. Its camera and
alarm systems must meet privacy and noise rules.
Solution 3 must follow strict privacy laws. If it controls safety systems, it may need
official approval. Clear policies for recording and storing video data are required.
Choice and Justifications
Solution 1 is the most practical and realistic option because it balances simplicity, cost,
and effectiveness. It can be built and deployed quickly using affordable components,
and it doesn’t require advanced robotics or AI expertise. The system provides reliable
safety alerts for PPE, air quality, smoke, and machine activity, making it suitable for
medium-sized workshops. It also supports sustainability by using low-energy sensors
and locally available parts, while legal compliance is straightforward with basic privacy
and safety standards. Overall, it delivers strong safety improvements without the
complexity or high cost of the other solutions.
References
[1] “viAct | Danger Zone Detection for Construction Jobsites | AI Video Analytics
for Workplace Safety | Dangerous Situation Alert System | Hazardous Areas Access
Control | Unsafe Act Detection Alert,” [Link], 2025.
[Link] (accessed Sep. 28, 2025).
[2] “viAct | PPE Detection Solution for Construction Jobsites | Construction
Management Software | Construction Safety Solution | AI Video Analytics for
Workplace Safety,” [Link]. [Link]
[3] “Aluminum vs Stainless Steel: A Comparative Analysis - China
VMT,” [Link], 2024. [Link]
[Link]/blog/[Link] (accessed Sep. 28, 2025).
[4] “Carbon Steel: The Ultimate Guide – 4 Main Types, Properties, and
Applications - Mechanical Engineering,” Mechanical Engineering, Apr. 15, 2023.
[Link]
[5] “Oak Wood: A Complete Guide to Properties, Uses, Staining, and
More,” woodworkingzone, May 10, 2025. [Link]
wood-complete-guide/ (accessed Sep. 29, 2025).
[6] “Understanding the different types of plywood,” [Link].
[Link]
[7] Protolabs, “Polycarbonate: Advantages, Disadvantages, and
Applications,” [Link], 2025.
[Link]
[8]
D. Olsen, “What is Sand Casting and How Does It Work?,” MetalTek, Nov. 23, 2020.
[Link]
[9] Wikipedia Contributors, “Injection moulding,” Wikipedia, Apr. 09, 2019.
[Link]