Smart Industrial Safety in High-Noise Environments Using IoT and AI

High noise levels in industrial workplaces pose significant challenges to occupational safety, particularly with hearing protection and effective communication. Traditional hearing protection devices, while effectively attenuating harmful noise, often compromise situational awareness by excessively isolating workers from the acoustic environment and preventing the perception of critical auditory cues (e.g., emergency alarms), thereby introducing additional safety risks. This paper presents a smart industrial safety system that integrates Internet of Things (IoT) and artificial intelligence (AI) and is based on intelligent hearing protection devices to (a) selectively attenuate hazardous industrial noise while (b) preserving human speech and (c) reproduce targeted audio notifications to workers near malfunctioning or hazardous machinery. A real-time voice activity detection (VAD) model is employed to distinguish vocal components from background noise to adaptively control digital signal processing filters. Furthermore, indoor localization enables the delivery of targeted audio messages to workers in proximity to relevant events. Experimental evaluations on embedded hardware demonstrate that the selected VAD model operates well within real-time constraints and effectively supports dynamic noise filtering. Objective evaluation of the filtering stage using Mean Opinion Score (MOS), signal-to-noise ratio (SNR), and Harmonics-to-Noise Ratio (HNR) shows consistent quality improvements across all tested conditions, with MOS gains up to +118%, SNR increases between +10.4 and +29.0 dB, and HNR improvements up to +6.22 dB, indicating enhanced speech intelligibility and preservation of voice harmonic structure even under high-noise scenarios. Robustness validation of the VAD module across varying acoustic conditions confirms reliable speech detection performance, achieving perfect classification at +10 dB SNR, very high accuracy at 0 dB (98.3%, ROC AUC 0.998), and stable operation even at −7 dB SNR (79.8% accuracy, ROC AUC 0.878). The proposed architecture achieves a balanced trade-off between hearing protection and speech intelligibility while enhancing the effectiveness of safety communications in noisy industrial environments.