SETTE: A Human-Centric Framework for Operator Safety Monitoring in Industry 5.0

Manufacturing environments in Industry 5.0 demand adaptive, human-centric safety systems that can dynamically respond to evolving regulations and operational conditions. Despite technological advances, human error accounts for 70-90% of industrial accidents, highlighting the need for intelligent safety monitoring systems. We present SETTE - Safety Environment using Tracking and run time, where validated rules are enforced through real-time monitoring using IoT sensors, computer vision, and wearables integrated with an AI-powered Safety Management System. A key innovation is the human-in-the-loop validation process, where safety experts interact with automatically generated Extended Reality scenarios to assess rule feasibility before deployment, ensuring both regulatory compliance and practical applicability. The framework maintains full traceability between generated rules and source regulations while providing adaptive, context-aware guidance through a conversational Human-Machine Interface. We illustrate the framework’s operational logic through a running example involving machine guarding rules for rotating machinery, showing how regulatory text can be systematically transformed into executable safety rules with complete audit trails. Unlike traditional static safety protocols, SETTE enables continuous adaptation to changing regulations and operational conditions, providing a transparent safety layer that enhances worker understanding and compliance while reducing human error in manufacturing environments.