Wearer Protection
Every wearer. Every shift. Fully covered.
A three-layer protection system that checks every active wearer against their full PPE entitlement. Gaps trigger automatic replacement orders. Zero-coverage situations trigger emergency dispatch.
The problem
The gap nobody sees until someone gets hurt.
A firefighter starts their shift. Their structural jacket was condemned yesterday after a hard-fail inspection — moisture barrier integrity compromised. The inspector recorded it. The system flagged it. But nobody told the station.
The wearer turns up, opens their locker, and the jacket is not there. No replacement has been sent. They are now on active duty without a compliant set of fire kit.
This is the gap. Not a record-keeping failure — a protection failure. The condemnation was recorded correctly. But recording what happened is not the same as preventing what happens next.
Architecture
Three layers. No gap goes undetected.
Each layer catches what the others might miss. Together, they guarantee that every wearer with upcoming shifts has a complete, compliant set of PPE.
Instant
Fires on every condemnation
When a garment is condemned, lost, or quarantined, the system immediately rechecks every affected wearer. Replacement orders created before the next shift.
Daily
Full scan — configurable time
Every active wearer with upcoming shifts is checked against their complete PPE entitlement. Gaps identified, replacement orders raised, route allocations made.
Hourly
Safety net — catches edge cases
A catch-all sweep that rechecks all wearers with upcoming shifts. Catches shift changes, late data entry, and manual stock adjustments. Nothing slips through.
Instant
Fires on every condemnation
When a garment is condemned, lost, or quarantined, the system immediately rechecks every affected wearer. Replacement orders created before the next shift.
Daily
Full scan — configurable time
Every active wearer with upcoming shifts is checked against their complete PPE entitlement. Gaps identified, replacement orders raised, route allocations made.
Hourly
Safety net — catches edge cases
A catch-all sweep that rechecks all wearers with upcoming shifts. Catches shift changes, late data entry, and manual stock adjustments. Nothing slips through.
Protection engine
See what the system detects.
The Protection Engine evaluates every active wearer against every product entitlement. Gaps are classified by severity and routed to the correct response — scheduled replacement or emergency dispatch.
This is not a dashboard. It is a prescriptive system that detects problems, classifies urgency, and creates the actions needed to resolve them — without waiting for someone to notice.
Protection Engine
Three layers: instant recheck on every condemnation, daily bulk scan, hourly safety net. Checks every active wearer against their PPE entitlement — including wearers currently on shift. When coverage drops to zero, the system responds immediately.
If a wearer is on shift with no compliant PPE, the system checks whether emergency dispatch can reach the station before the shift ends. If it can — immediate dispatch. If it can't, ops is alerted and a replacement order is created for the next shift, but only if the garments won't return through the normal pipeline in time.
Contamination triggers a dedicated decon workflow — isolation, specialist assessment, conditional reissue or condemnation. Coverage gaps from quarantine are detected by the hourly safety net.
"It fired thirteen minutes after the condemnation."
Replacement Orders
28/07/2026Dave Hendricks
Westshire Station 2
Coverage zero — both structural jackets quarantined (contamination). On shift, no compliant PPE.
Status
On shift now
Shift ends
18:00
SMS sent
12:13
Emergency courier en route — ETA before 18:00 shift end
Second order raised for 22:00 shift — normal pipeline won't return garments in time
Sarah Mitchell
Westshire Station 4
Condemned — max wash life reached (R-001). Scheduled route delivers before shift.
Tom Reeves
Westshire Station 1
Trousers condemned at inspection — reproof failure (R-003). Buffer stock allocated.
Priority model
Two priorities. Different response paths.
Buffer stock available. Scheduled route.
- ●Replacement garment allocated from buffer stock
- ●Added to the next scheduled route for that station
- ●Wearer will have replacement before their next shift
- ●Ops manager notified via portal
Zero PPE. Wearer on shift. Emergency dispatch.
- ●No compliant garment available — wearer has zero coverage
- ●SMS alert to ops manager immediately
- ●Email alert to client H&S manager
- ●Portal alert with full gap detail
- ●Emergency dispatch created — outside normal route schedule
Representative view
See the real system in a demo.
Product recall
Respond to manufacturer recalls in minutes. Not weeks.
When a manufacturer issues a recall, you need to know which wearers are affected, where those garments are, and what to replace them with. The system identifies every affected garment across every client and every station within seconds of the recall being entered.
Swap one product for another across all wearers. Entitlements, allocations, and replacement orders update automatically. The Protection Engine recalculates coverage for every affected wearer and raises replacement orders immediately — no manual spreadsheet reconciliation.
Delivery methods
Three ways to get fire kit to the wearer.
Every replacement follows one of three delivery paths. The system selects the method based on urgency, route schedule, and wearer preference.
Add to Next Route
The replacement garment is injected into the next scheduled delivery for that station. No extra trip. No additional cost. The driver picks it up as part of their normal run.
Standard priority
Emergency Courier
An ad-hoc route created outside the normal schedule. Used when the wearer is on shift and has zero coverage. Same-day dispatch. Ops manager alerted by SMS.
Urgent priority
Counter Collection
The wearer picks up the replacement garment at the plant. Used when the wearer is nearby or prefers to collect. The system reserves the item and notifies the wearer when it is ready.
Wearer-initiated
Entitlement templates
Define the PPE set once. Every new wearer inherits it automatically.
Contract entitlement templates define exactly which PPE items each contract requires — structural jacket, structural trousers, flash hood, gloves, helmet, boots. Quantities, sizes, and replacement cycles are all specified in the template.
When a new wearer is added, their allocation is created automatically from the template. No manual entry. No missed items. The Protection Engine immediately knows what that wearer needs and begins tracking coverage from day one.
When a contract changes — a new product added, an item quantity increased — the template is updated once and the system recalculates entitlements for every wearer on that contract.
Watch Rota Integration
4-watch pattern. The portal knows who is on shift.
Fire services operate on a 4-watch rotation — Red, Blue, Green, and White. Vorrex models the full watch pattern: crew membership, shift calculation, and handover timing. The portal shows coverage for the watch that is currently on duty, not just a static list of all wearers.
When an H&S manager opens the coverage grid, they see the on-shift watch highlighted first. Coverage gaps for on-duty firefighters are prioritised over gaps for watches that are stood down. The Protection Engine uses the same watch calendar — urgent alerts only fire for wearers who are actually on shift.
Watch assignments are managed in the portal. When a firefighter moves between watches or a new crew member joins, the H&S manager updates the assignment and the system recalculates coverage immediately.
Watch rota details
- 4-watch patternRed, Blue, Green, White
- Crew membershipwearers assigned to watches
- Shift calculationsystem knows who is on duty
- On-shift prioritycoverage gaps ranked by duty status
- Portal-managedH&S updates watch assignments
Temporary Allocation
Loaner PPE with auto-expiry. No coverage gaps while replacements are processed.
When a wearer's garment is condemned, they may need PPE immediately — before the replacement is manufactured, processed, and delivered. Temporary allocation provides loaner garments from pool stock with a 14-day auto-expiry.
The system tracks temporary garments separately from permanent entitlements. After 14 days, the temporary allocation expires and the garment is automatically recalled. This prevents over-entitlement — wearers do not end up with more kit than their contract specifies.
The portal shows temporary allocations clearly distinguished from permanent assignments. H&S managers see which wearers have loaner kit, when it was issued, and when the auto-recall is scheduled.
Temporary allocation workflow
- Garment condemnedcoverage gap detected
- Loaner issued from poolimmediate coverage restored
- 14-day auto-expirysystem tracks countdown
- Auto-recall triggeredloaner returned to pool
- Permanent replacement arriveswearer fully covered
Pipeline-Aware Coverage
The system knows what is coming back — and when.
The Protection Engine does not just check current stock levels. It tracks every garment moving through the processing pipeline — in wash, in inspection, in repair — and estimates when each will return to service using historical averages with confidence blending.
A 20% safety margin is applied to all pipeline return estimates. If the system predicts a garment will be back in 3 days, it plans for 3.6. This means coverage decisions account for real-world delays without triggering unnecessary replacement orders.
The portal reflects this intelligence. When an H&S manager drills into a coverage gap, they see not just what is missing — but what is in the pipeline, where it is in the process, and the estimated return date. Fewer unnecessary calls to the laundry.
Pipeline tracking
- In washestimated return based on wash cycle history
- In inspectionaverage inspection turnaround applied
- In repairrepair type determines estimate
- Confidence blendinghistorical averages weighted by recency
- 20% safety marginbuilt into every estimate
Replacement Approval (COPE)
Client-side approval before dispatch.
When a garment is condemned and a replacement order is raised, the H&S manager can review and approve it before dispatch. The COPE (Client Order Process Engine) workflow gives clients control over replacement spend without slowing down urgent orders.
The H&S manager sees the condemned garment, the reason for condemnation, the proposed replacement, and the cost. They approve, query, or reject. Approved orders move to pick and dispatch. Queried orders are returned to the laundry with a note. Urgent replacements — zero-coverage situations — bypass approval and dispatch immediately.
COPE workflow
- Replacement order raisedauto on condemnation
- H&S manager reviewsreason, item, cost visible
- Approve / query / rejectone-click action
- Approved orders dispatchedadded to next route
- Urgent bypasszero-coverage skips approval
Contamination Reporting
Wearer reports contamination. Quarantine workflow starts automatically.
Wearers report contamination directly via the app — selecting the type of exposure and the affected garments. The system creates a decon bag record automatically, flags the garments for quarantine, and initiates the decontamination workflow.
The contaminated garments are isolated from the normal processing flow. Collection is scheduled on a separate manifest. At goods-in, the quarantine flag ensures contaminated items are routed to the correct decon wash programme — never mixed with standard laundry.
Contamination workflow
- Wearer reports via appexposure type selected
- Decon bag createdautomatic on report
- Garments quarantinedflagged in system
- Separate collection manifestisolated transport
- Decon wash programmerouted automatically
Wearer Bundles
Personal kit. Grouped, labelled, and delivered to their station.
Every wearer's garments are grouped into a personal bundle — labelled with their name and station. This is not pool stock distributed at random. Each bundle contains the exact garments allocated to that wearer, packed together for direct handover.
The bundle system ensures the right kit goes to the right person every time. No sorting at the fire station. No confusion over whose jacket is whose. The wearer receives their personal set, ready to go.
Bundle status is visible in the portal. H&S managers can see which bundles are in transit, which have been delivered, and which are awaiting processing at the laundry.
Bundle features
- Personal allocationgarments assigned to individual wearers
- Grouped and labelledname and station on every bundle
- Station deliverydirect to the wearer's location
- Portal visibilitybundle status tracked live
- No station sortingready to hand over on arrival
FAQ
Common questions
How does Vorrex prevent a firefighter from going on shift without PPE?
Vorrex uses a three-layer protection engine. Layer 1 runs daily at 06:00, checking every wearer with an upcoming shift against their PPE entitlements. Layer 2 fires instantly when a garment is condemned, lost, or quarantined — rechecking that wearer within milliseconds. Layer 3 is an hourly safety net that catches edge cases. If any layer detects a gap, a replacement order is raised automatically with the appropriate priority level.
What is a coverage gap in PPE management?
A coverage gap occurs when a firefighter does not have a compliant garment for every PPE category they are entitled to under their contract. For example, if their structural jacket is condemned and no replacement is available before their next shift, that is a coverage gap. Vorrex detects these gaps automatically and raises replacement orders before the shift starts.
How fast can Vorrex detect a missing garment?
The event-driven protection layer (Layer 2) detects coverage gaps within milliseconds of a garment being condemned, lost, or quarantined. It fires via MediatR domain events, so there is no polling delay. Replacement orders with EMERGENCY priority are raised immediately if the wearer is currently on shift.
See the Protection Engine on real data.
45 minutes. We'll run the engine against real data and show you exactly how gaps are detected, classified, and resolved — before anyone starts their shift.