/ Case Studies / Preventing Costly Downtime with AI and Computer Vision Case Studies Preventing Costly Downtime with AI and Computer VisionConcurrency helped a leading energy and logistics provider eliminate costly sand spills by developing a Computer Vision–based IoT solution that detects open truck hatches and triggers real-time alerts—improving safety, efficiency, and reliability.Critical IssueA major energy logistics company faced repeated operational delays due to sand spills caused by trucks leaving loading sites with open hatches. Each spill resulted in hours of cleanup and lost productivity. The organization knew the issue existed but lacked the right technology and expertise to automate detection and prevention.They partnered with Concurrency to design and deploy a custom AI and IoT solution capable of identifying when a truck’s bottom hatch was open and immediately notifying operators—preventing spills before they happened.Customer ProfileLeading provider of materials and logistics solutions for the energy industryKey ProblemThe company needed a way to leverage existing camera feeds to detect operational errors in real time. Without AI-driven monitoring or automated workflows, spills continued to cause downtime, operational costs, and safety risks.BUSINESS CHALLENGESBefore engaging with Concurrency, the organization faced several key challenges:Unplanned Downtime: Each spill caused hours of cleanup and halted operations.Limited Data Utilization: Cameras were already installed but not used intelligently.Operational Inefficiency: Continuous trucking operations left little room for manual oversight.Lack of Automation: No system existed to proactively identify open hatches or alert staff.OutcomesOperational ReliabilityAI-driven detection now prevents sand spills before they occur, eliminating costly downtime and cleanup.Smart IoT IntegrationConcurrency connected existing camera infrastructure with intelligent computer vision models to automate detection and alerting.Efficiency & Cost SavingsBy automating incident prevention, the client gained significant time savings and operational consistency—supporting nonstop delivery operations.our solutionComputer Vision with IoT IntegrationDeveloped and trained a custom vision model to detect open truck hatches in real time.Integrated IoT data from on-site cameras to enable automated analysis and alerts.Automated Alerting & WorkflowBuilt an AI-powered workflow to notify operators immediately when a hatch is detected open.Enabled quick corrective action, preventing spills before they occur.Collaborative PartnershipLeveraged Concurrency’s expertise in AI, automation, and low-code solutions.Partnership originated from a trusted local connection, leading to rapid engagement and solution success.LESSONS LEARNED & NEXT STEPSEven simple camera systems can become powerful operational tools with AI integration.Automation delivers measurable ROI by reducing human oversight needs.Strong relationships and local collaboration accelerate innovation.The organization now plans to expand computer vision capabilities to additional operational sites—continuing its investment in AI-driven reliability and safety.CONCLUSIONBy partnering with Concurrency, this energy and logistics provider transformed a persistent operational problem into a data-driven success story. Through Azure-based AI, IoT integration, and intelligent automation, the company now prevents costly sand spills, safeguards uptime, and strengthens its foundation for ongoing digital innovation.
