With over 1,400 personnel and around-the-clock operations, Logan Aluminum is deeply committed to team member wellbeing underpinned by a proactive approach to safety. The company supplies high-quality rolled aluminum primarily for beverage cans, operating on a 24/7 schedule that includes overnight and weekend shifts. Supporting its vision to eliminate all “life changing injuries”, the company regularly identifies and mitigates high-risk scenarios before incidents occur by implementing initiatives focused on preventing serious injury and fatality. One such initiative was the installation of Guardian in 2024.

In late 2023, the leadership team at Logan Aluminum began discussing operator fatigue – particularly in the demanding Reversing Mill operations. The conversation sparked an initiative to explore advanced safety technologies that could help operators stay alert during their long, high-focus shifts.

That search led to Seeing Machines, via Caterpillar’s longstanding success with the technology across the mining industry. After initial discussions and due diligence to ensure compatibility with existing systems, Logan Aluminum initiated a pilot project. By early 2024, the company had developed a full implementation plan, gained leadership and team member buy-in, and completed the first Guardian installation in May 2024.

“Fatigue is a recognised concern in any industrial setting,” explains Steven Clarke, President of Logan Aluminum. “We are always searching for technologies that we can use to help us keep our people safe. Seeing Machines’ technology and adaptation to our process and concerns, combined with collaborative change management, has proven to be a successful formula.”

While Guardian is typically installed in heavy vehicles, Logan Aluminum required a customised approach. In the Reversing Mill, where operators manage the reduction of aluminum slabs through multiple high-pressure passes, the traditional vehicle-based Guardian system needed modification as the operator pulpit is stationary. Working closely with Seeing Machines and their own engineering team, Logan Aluminum created a coding solution that activates Guardian only when the mill is running and specific criteria – like mill speed and pass count – are met. This ensures that fatigue alerts are triggered only when safety risks are highest, eliminating unnecessary distractions during non-critical moments.

In addition to the Reversing Mill, Logan Aluminum’s yard dog fleet – used to transport slabs across the facility – also benefits from Guardian’s real-time fatigue monitoring. The system provides immediate alerts for signs of microsleeps or drowsiness, allowing operators to take quick, corrective action.

Since implementation, Logan Aluminum has already seen meaningful results. Operators report a heightened sense of self-awareness regarding their fatigue levels and are proactively taking steps such as standing up, stretching, or taking a short break, when prompted by the system. This behavioural shift is contributing to a safer and more productive work environment.

The technology also aligns seamlessly with the company’s culture of self-managed teams and proactive safety. Adoption was carefully managed through open communication, transparency, and clear messaging that highlighted Guardian was there to support, not punish. Early scepticism was quickly overcome as team members saw firsthand how the system helped them manage their own wellbeing. Monthly reports are anonymised, and only in the case of repeated alerts is the operator – not management – notified.

This mature approach to safety doesn’t just benefit team members, it also benefits the business. Customers see the company’s investment in cutting-edge safety technology as a reflection of its unwavering dedication to quality and continuous improvement.

“Our customers know that Logan is serious about safety,” Clarke concluded. “Investing in Guardian shows we’re willing to go above and beyond to protect our operators and ensure smooth, uninterrupted operations. That level of commitment builds trust with our clients and strengthens our position in the market.”

With its strong focus on innovation, a culture of trust and accountability, and the strategic use of advanced technologies like Guardian, Logan Aluminum continues to lead by example in industrial safety and performance. Learn more in this case study.