Case Study: USG Boral achieves real-time AI-powered warehouse safety and near-real-time analytics with AWS IoT

USG Boral Launches a Trailblazing AI Safety System on AWS

USG Boral, a leading manufacturer of gypsum‑based wall and ceiling systems across Asia Pacific and the Middle East, needed to move beyond manual CCTV review after a 2018 forklift–pedestrian collision and implement a proactive, preventive safety solution. Working with partner Bigmate on the AWS platform, the project used AWS IoT technologies—particularly AWS IoT Greengrass and AWS IoT Core—along with AWS Lambda and Amazon SageMaker to build an AI system that detects and prevents warehouse incidents.

The resulting Warny™ solution, built on AWS IoT, performs near‑real‑time vision analytics (processing ~12 images per second with latency under 300 ms), sounds local alarms when objects enter a 1‑meter safety radius, and pushes dashboards, reports, texts, and emails for rapid follow‑up and re‑education. Warny has been tested in Australia with expansion to additional sites planned, delivers unified safety metrics without hiring data scientists, and provides a scalable framework for further ML-driven safety features.

USG Boral

Calvin Ng

IT Director, Infrastructure and ANZ