AI-Powered Safety System Boosts Manufacturing Efficiency at Minalex

[CITY, STATE] – November 12, 2025 – Minalex, a prominent manufacturer of aluminum extrusions, is deploying an AI-powered visual inspection system to enhance worker safety, improve quality control, and streamline production processes. The move, a collaboration with Dunaway Technology, reflects a growing trend in the manufacturing sector where artificial intelligence is moving beyond experimental stages and becoming integrated into core operations.

Dubbed ‘Detect-It AI,’ the system utilizes high-speed cameras and sophisticated algorithms to monitor operator behavior in real-time, identifying potential safety hazards and irregularities before they escalate. Beyond safety, Minalex anticipates leveraging the technology to assess product quality, guide production adjustments, and enhance overall operational efficiency.

“We’re excited about the potential of AI to create a safer and more efficient work environment,” said a company representative. “Our initial focus is on protecting our employees, but we see opportunities to optimize our processes and deliver even higher quality products to our customers.”

A Shift Towards Proactive Safety

Traditionally, manufacturing safety relied heavily on reactive measures – addressing hazards after they occurred. However, the rise of AI is enabling a shift towards proactive safety, where potential risks are identified and mitigated before they lead to incidents.

“The beauty of this technology is its ability to continuously monitor and analyze data, detecting anomalies that a human operator might miss,” explained an industry analyst. “It's like having an extra set of eyes on the production line, constantly scanning for potential problems.”

Detect-It AI operates by establishing “net parameters” for acceptable operator behavior. When an action deviates from these parameters – such as entering a restricted zone or failing to wear appropriate protective gear – the system triggers an alert, allowing supervisors to intervene. This proactive approach minimizes the risk of accidents and injuries, while also improving overall production efficiency.

Beyond Safety: Quality Control and Optimization

While worker safety is the primary initial focus, Minalex is also exploring the potential of Detect-It AI to enhance quality control and streamline production processes. The system’s ability to analyze visual data in real-time can be used to identify defects, assess product dimensions, and monitor finish quality with greater accuracy and speed than manual inspections.

“We anticipate using the system to confirm product dimensions, assess finish quality earlier in the process, and guide adjustments based on real-time data,” explained a company source. “This will help us reduce waste, improve product consistency, and deliver even higher-quality products to our customers.”

AI Adoption in Manufacturing: A Growing Trend

Minalex’s investment in AI reflects a broader trend in the manufacturing sector. According to recent industry reports, approximately 95% of manufacturers are either investing in or planning to invest in AI/Machine Learning within the next five years. The global AI in manufacturing market is projected to reach approximately $230.95 billion by 2034, demonstrating a compound annual growth rate (CAGR) of 44.2%.

Key applications of AI in manufacturing include predictive maintenance, quality control, process optimization, and supply chain management. AI-powered systems are being used to monitor equipment health, predict potential failures, optimize production parameters, and improve inventory management.

“AI is transforming the manufacturing landscape,” stated an industry expert. “It’s enabling companies to operate more efficiently, reduce costs, improve quality, and enhance safety.”

On-Premises Deployment: A Focus on Data Security

A key aspect of Minalex’s implementation is the decision to deploy Detect-It AI on-premises. This means that all data is processed and stored locally, rather than being sent to a cloud-based server.

“Data security and privacy are paramount,” explained a company representative. “By keeping our data on-premises, we can ensure that it remains secure and protected from unauthorized access.”

This approach aligns with a growing trend in the manufacturing sector, where companies are increasingly concerned about the security of their data. On-premises deployment allows companies to maintain greater control over their data, while also reducing the risk of cyberattacks and data breaches.

Competition and Innovation in AI-Powered Manufacturing

Minalex isn't alone in embracing AI-powered manufacturing solutions. Companies across the aluminum extrusion and broader manufacturing sectors are actively exploring and implementing AI technologies to enhance their operations.

Novelis, for instance, has successfully implemented AI in aluminum rolling and recycling, while Constellium Valais SA is leveraging AI to study the manufacturability of new aluminum elements. D-Cube Immersive Solutions offers “CYRUS,” an AI-driven in-line quality assurance solution specifically for aluminum extrusion, also with an on-premise option for data security.

This competitive landscape is driving innovation and accelerating the adoption of AI in manufacturing. As AI technologies continue to evolve, manufacturers are expected to increasingly leverage these tools to gain a competitive advantage and improve their bottom line.

The Future of AI in Manufacturing

As AI technologies continue to mature, the potential applications in manufacturing are virtually limitless. Experts predict that AI will play an increasingly important role in driving automation, optimizing processes, and enhancing decision-making.

“We’re just scratching the surface of what’s possible with AI in manufacturing,” stated an industry analyst. “In the years to come, we can expect to see even more sophisticated and integrated AI solutions that transform the way manufacturers operate.”

With the growing demand for efficiency, quality, and safety, AI is poised to become an indispensable tool for manufacturers in the 21st century. Companies that embrace AI and invest in these technologies will be well-positioned to thrive in the years to come.