Connected fleet technologies such as intelligent safety systems and telematics are increasingly being deployed by the warehouse industry to improve productivity, increase safety and gain operational insights.

One of the most effective warehouse safety innovations has been the introduction of blue warning lights on forklifts and other equipment, says CFAO Equipment national technical manager Stephen Mostert.

Blue lights project a visible beam 3 m to 4 m ahead of the equipment, warning pedestrians and operators of approaching equipment, especially at intersections or aisle crossings. The projected blue light acts as an early visual warning sign, helping to improve awareness and reduce the risk of collisions.

Mostert say what started as a preventative safety tool has evolved into an industry norm. “Today, all forklifts leaving our workshops are fitted with blue lights because customers recognise the value they bring in improving visibility and enhancing safety.

“Blue lights are especially valuable in high-density warehouse operations where multiple forklifts and pedestrians operate close to each other. Combined with beacon lights, reverse buzzers and warehouse recommended speed controls, they form part of a broader safety ecosystem designed to protect both operators and pedestrians,” he adds.

The I Site telematics platform designed by Toyota Material Handling (TMH) can be used to give warehouse managers a comprehensive, real-time overview of fleet operations, operator behaviour and equipment utilisation. The system enables businesses to monitor how equipment is being used, identify inefficiencies and proactively manage safety risks.

The system offers the following capabilities:

• Measure forklift utilisation and identify underused or overused equipment 
• Track operator activity and driving behaviour 
• Monitor impacts and collisions 
• Provide global positioning system tracking and zoning 
• Notify managers if equipment leaves designated premises 
• Record operational data for reporting and analysis 

“All incidents and operational activities are recorded, giving managers a bird’s-eye view of their entire fleet operation. The result is improved cost control, enhanced efficiencies and safer equipment operations,” notes Mostert.

TMH has also developed the Sens+8 pedestrian protection system (PPS) aimed at further improving warehouse safety. Using intelligent camera technology integrated into the equipment’s electronic systems, Sens+8 detects obstacles or pedestrians behind the machine and actively intervenes to prevent collisions.

As equipment such as a forklift, approaches an obstacle, the system warns the operator by means of an alarm and, if the operator fails to respond, the machine automatically reduces speed and, if necessary, brings the machine to a complete stop.

The PPS is available across TMH’s counterbalance equipment, including diesel-powered equipment.