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Leveraging Digital Transformation for Enhanced Occupational Health and Safety in Manufacturing

A special issue of Applied Sciences (ISSN 2076-3417).

Deadline for manuscript submissions: closed (20 June 2025) | Viewed by 3890

Special Issue Editors


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Guest Editor
Department of Computer, Control and Management Engineering “Antonio Ruberti”, Sapienza University of Rome, Via Ariosto 25, 00185 Rome, Italy
Interests: safety; resilience; smart factory; supply chain; digitalization
Special Issues, Collections and Topics in MDPI journals

E-Mail Website
Guest Editor
Department of Computer, Control and Management Engineering “Antonio Ruberti”, Sapienza University of Rome, Via Ariosto 25, 00185 Rome, Italy
Interests: smart factory; Industry 4.0; Industry 5.0; large language models; safety; cybersecurity

E-Mail Website
Co-Guest Editor
Department of Mechanical and Aerospace Engineering, Sapienza University of Rome, Via Eudossiana 18, 00184 Rome, Italy
Interests: technological introduction on health and safety in the workplace within manufacturing sectors; methodologies to guide adaptive automation

Special Issue Information

Dear Colleagues,

The integration of digital technologies is revolutionizing the field of occupational health and safety. This Special Issue explores the industrial impact of enabling technologies such as virtual reality, augmented reality, and generative artificial intelligence, focusing on occupational health and safety (OHS). In high-risk, complex manufacturing environments, the use of innovative tools can significantly improve safety standards, reduce hazards, and promote a culture of preventive maintenance and risk management. Here, the use of digital technologies—such those cited—enables the development of novel tools that promote learning through actions, storytelling, and a first-person experiences-based approach. Furthermore, it permits the integration of non-traditional training content and modes, thereby addressing the inherent variability in digitized industrial contexts. In such a context, it is not sufficient to learn rules and behaviors that are required. Ad-hoc adaptation and response to unpredictable conditions must also be learned. Therefore, in the field of safety management, a new level of expertise is needed. The Skill–Rule–Knowledge framework contains an exemplary level of knowledge. This framework helps one to understand the different levels of conscious effort that workers must apply to industrial tasks and how this affects decision-making. In the event of a unique and unfamiliar situation, the decision is not automatic and reflexive (skill-based), and there are no rules to guide the decision maker (rule-based). So, it is evident that a knowledge-based decision is needed, i.e., the creation of plans and responses based on personal knowledge and experience. In the pursuit of a sustainable working environment, all these concerns must be addressed. So, this Special Issue explores how these technologies can support training, enhance safety protocols, and improve incident management processes. Submissions are invited to present frameworks, models, experimental studies, and practical applications that integrate technologies to support OHS and enhance the social, economic, and environmental sustainability of industrial environments.

Topics of interest include but are not limited to the following: Innovative uses of immersive technologies for safety training, demonstrating impacts on workers' skills and capabilities; Development and application of AI models for the analysis of safety incident narratives and protocols to identify trends and preventive measures; Comparative analyses of industrial safety performance before and after the adoption of technologies, highlighting their effectiveness and potential improvement.

Prof. Dr. Francesco Costantino
Dr. Silvia Colabianchi
Dr. Margherita Bernabei
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Applied Sciences is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2400 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • training
  • safety management
  • smart manufacturing
  • sustainable digitization
  • virtual reality
  • augmented reality
  • generative artificial intelligence

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Published Papers (4 papers)

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Research

28 pages, 2693 KiB  
Article
Assessing Resilience Practices in the Digital Transformation Era: A Storytelling-Based Cross-Sectional Study in Italy
by Sara Stabile, Rosina Bentivenga, Emma Pietrafesa, Edvige Sorrentino, Margherita Bernabei, Silvia Colabianchi and Francesco Costantino
Appl. Sci. 2025, 15(11), 6291; https://doi.org/10.3390/app15116291 - 3 Jun 2025
Viewed by 263
Abstract
This study applies Safety II principles within a storytelling- and RAG-based questionnaire to explore how resilience engineering (RE) principles and practices are perceived and implemented in Italy’s manufacturing sector. Before completing the questionnaire, accident and near-miss scenarios were presented through narrative stories. The [...] Read more.
This study applies Safety II principles within a storytelling- and RAG-based questionnaire to explore how resilience engineering (RE) principles and practices are perceived and implemented in Italy’s manufacturing sector. Before completing the questionnaire, accident and near-miss scenarios were presented through narrative stories. The cross-sectional study on 334 companies reveals that Monitor and Respond are prioritized over Anticipate and Learn, with medium-large companies and those adopting technological innovations showing more advanced resilience-oriented OSH management practices. The study emphasizes the importance of company size and technological adoption in shaping safety practices, recommending investment in innovative solutions and fostering a culture that addresses near misses to prevent severe accidents and support continuous improvement. Full article
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39 pages, 13529 KiB  
Article
Intelligent Monitoring of BECS Conveyors via Vision and the IoT for Safety and Separation Efficiency
by Shohreh Kia and Benjamin Leiding
Appl. Sci. 2025, 15(11), 5891; https://doi.org/10.3390/app15115891 - 23 May 2025
Viewed by 418
Abstract
Conveyor belts are critical in various industries, particularly in the barrier eddy current separator systems used in recycling processes. However, hidden issues, such as belt misalignment, excessive heat that can lead to fire hazards, and the presence of sharp or irregularly shaped materials, [...] Read more.
Conveyor belts are critical in various industries, particularly in the barrier eddy current separator systems used in recycling processes. However, hidden issues, such as belt misalignment, excessive heat that can lead to fire hazards, and the presence of sharp or irregularly shaped materials, reduce operational efficiency and pose serious threats to the health and safety of personnel on the production floor. This study presents an intelligent monitoring and protection system for barrier eddy current separator conveyor belts designed to safeguard machinery and human workers simultaneously. In this system, a thermal camera continuously monitors the surface temperature of the conveyor belt, especially in the area above the magnetic drum—where unwanted ferromagnetic materials can lead to abnormal heating and potential fire risks. The system detects temperature anomalies in this critical zone. The early detection of these risks triggers audio–visual alerts and IoT-based warning messages that are sent to technicians, which is vital in preventing fire-related injuries and minimizing emergency response time. Simultaneously, a machine vision module autonomously detects and corrects belt misalignment, eliminating the need for manual intervention and reducing the risk of worker exposure to moving mechanical parts. Additionally, a line-scan camera integrated with the YOLOv11 AI model analyses the shape of materials on the conveyor belt, distinguishing between rounded and sharp-edged objects. This system enhances the accuracy of material separation and reduces the likelihood of injuries caused by the impact or ejection of sharp fragments during maintenance or handling. The YOLOv11n-seg model implemented in this system achieved a segmentation mask precision of 84.8 percent and a recall of 84.5 percent in industry evaluations. Based on this high segmentation accuracy and consistent detection of sharp particles, the system is expected to substantially reduce the frequency of sharp object collisions with the BECS conveyor belt, thereby minimizing mechanical wear and potential safety hazards. By integrating these intelligent capabilities into a compact, cost-effective solution suitable for real-world recycling environments, the proposed system contributes significantly to improving workplace safety and equipment longevity. This project demonstrates how digital transformation and artificial intelligence can play a pivotal role in advancing occupational health and safety in modern industrial production. Full article
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31 pages, 7146 KiB  
Article
Resilience Analysis Grid–Rasch Rating Scale Model for Measuring Organizational Resilience Potential
by Andrea Falegnami, Andrea Tomassi, Giuseppe Corbelli and Elpidio Romano
Appl. Sci. 2025, 15(4), 1695; https://doi.org/10.3390/app15041695 - 7 Feb 2025
Cited by 1 | Viewed by 996
Abstract
This paper presents a novel method for measuring organizational resilience by integrating the Rasch model into the Resilience Analysis Grid (RAG), providing a robust and objective tool for cross-sectional resilience studies. By treating the four cornerstones of resilience as abilities, Rasch’s model allows [...] Read more.
This paper presents a novel method for measuring organizational resilience by integrating the Rasch model into the Resilience Analysis Grid (RAG), providing a robust and objective tool for cross-sectional resilience studies. By treating the four cornerstones of resilience as abilities, Rasch’s model allows for an assessment that positions both the difficulty of the items and the organizations’ ability along a common scale. The requirement is the availability of a number of different organizations to be assessed. We employ a dataset generated through an artificial simulation and analyzed in a controlled environment, demonstrating the potential of Rasch-based resilience assessments to provide accurate, comparable, and scalable results in different organizational contexts. The traditional RAG is designed without a normative reference group, which makes it challenging to evaluate its results. The proposed model overcomes this limitation by offering a measurement scale on which different organizations can be placed without the need to use a normative group, facilitating the more consistent and timely monitoring of systems. This novel approach to quantifying resilience potentials highlights the transformative role of digital technologies in improving workplace safety and resilience. It advances resilience engineering and occupational health and safety practices in complex environments like manufacturing and industrial sectors. Full article
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21 pages, 2265 KiB  
Article
A Generative Artificial-Intelligence-Based Workbench to Test New Methodologies in Organisational Health and Safety
by Andrea Falegnami, Andrea Tomassi, Giuseppe Corbelli, Francesco Saverio Nucci and Elpidio Romano
Appl. Sci. 2024, 14(24), 11586; https://doi.org/10.3390/app142411586 - 11 Dec 2024
Cited by 4 | Viewed by 1221
Abstract
This paper introduces a novel generative artificial intelligence workbench specifically tailored to the field of safety sciences. Utilizing large language models (LLMs), this innovative approach significantly diverges from traditional methods by enabling the rapid development, refinement, and preliminary testing of new safety methodologies. [...] Read more.
This paper introduces a novel generative artificial intelligence workbench specifically tailored to the field of safety sciences. Utilizing large language models (LLMs), this innovative approach significantly diverges from traditional methods by enabling the rapid development, refinement, and preliminary testing of new safety methodologies. Traditional techniques in this field typically depend on slow, iterative cycles of empirical data collection and analysis, which can be both time-intensive and costly. In contrast, our LLM-based workbench leverages synthetic data generation and advanced prompt engineering to simulate complex safety scenarios and generate diverse, realistic data sets on demand. This capability allows for more flexible and accelerated experimentation, enhancing the efficiency and scalability of safety science research. By detailing an application case, we demonstrate the practical implementation and advantages of our framework, such as its ability to adapt quickly to evolving safety requirements and its potential to significantly cut down development time and resources. The introduction of this workbench represents a paradigm shift in safety methodology development, offering a potent tool that combines the theoretical rigor of traditional methods with the agility of modern AI technologies. Full article
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