Improving Safety in your Warehouse Operations

Pedestrian Safety

• Hazards• Pedestrian forklift interaction• Unauthorized access

• Common Methods Used to Reduce Risk• High visibility clothing• Clearly defined pedestrian walkways• Crosswalk intersection planning• Guarding and handrails• Signage• Blind spot mirrors• Forklift lighting• Access control

Pedestrian Safety

• High Visibility Clothing• Increases pedestrian and operator visibility

• Common Implementation Methods• Provide a selection of general use vests• Personal issued vests• Integrated high visibility uniforms

Pedestrian Walk Path Study

Forklift Traffic

Pedestrian Traffic

Cross Walk

Pedestrian Safety

• Pedestrian Walk Paths• Reduced forklift/pedestrian interaction• Controls and directs pedestrian traffic• Prevents unnecessary pedestrian traffic in

high traffic areas.• Provides a physical barrier of protection

• Forklift barrier – Prevents forklift from entering pedestrian walkway.

• Pedestrian barrier – Controls pedestrian access.

Pedestrian Barrier

Forklift Barrier

Pedestrian Safety

• Pedestrian Barriers• Restricts the flow of

pedestrian traffic in high traffic areas.

• Directs the flow of pedestrian traffic to intended crosswalks.

• Swing gates limit the continuous flow of pedestrian traffic.

Pedestrian Safety

Pedestrian Safety

Pedestrian Safety

• Forklift Barriers

• Physical barrier to prevent forklifts entering walkways.

• Eliminates storage encroachment into walkways.

Pedestrian Safety

• Floor Signs• Durable• Slip Resistant• Highly Visible• Increases Pedestrian Awareness• Warns of Forklift Traffic at Intersections• Useful in High Traffic Areas

Pedestrian Safety

• Handheld Electronics Use• Cell Phones

• Restricted from use in all warehouse areas

• Handheld Scanners• Restricted from use while operating forklift

• The Dangers of Taking Eyes of Task• You can only react to the hazards you see

Pedestrian Safety

• Blind Spot Mirrors• Mirrors offer blind spot protection at:

• Corners• Doorways• Intersections

• Forklift lights increase visibility in mirrors

Forklift Lighting

• Forklift lighting increases visibility in variety of ways.

• Increases visibility of the forklift to pedestrians• Headlights• Strobe Light• Blue Light

• Increases the visibility of pedestrians to the forklift operator

• Reflective clothing helps increase visibility

• Increases visibility and communication between forklift operators

• Headlights• Tail lights• Turn Signals

Forklift Lighting

• Blue LED light illuminates a blue circle on the floor 15 feet behind the forklift.

• Provides an early warning indicator that a forklift is backing up.

• Increases awareness of forklift traffic in blind intersections.

Dock Safety

• Driver Safety• Access control

• NOVA trailer locks• Dock plate transition

• Anatomy of the spine• Suspension seats• Tandem positioning• Dock plate transition

• Trailer up ending

Dock Safety

• Access Control• Prevents unauthorized access by

untrained personnel

• Limits pedestrian traffic at loading docks.

• Loading/Unloading Safety• Provides line-of-sight between

forklift operator and semi drivers preventing premature pull offs

Dock Safety

Video Presentation

Dock Safety

• Anatomy of the Spine• The amount of load on the disc

depends upon the posture/position of the individual.

• Stretching or reversing out of the work position offloads tissues and alleviates tension.

Dock Safety

• Adjustable Suspension Seats• Limit the amount of shock

• Speed of Dock Transition• Transition from dock to trailer

at walking speed.

• Shock absorbing seats reduce the amount of stress and strain on the spine.

Tandems to the Rear of the TrailerTandems Fully Forward

Dock Safety

Dock Safety

• Use of trailer jacks prevents trailer up-ending of uncoupled trailers.

• Supports trailer in the event of landing gear failure.

• Floors should be inspected prior to loading/unloading for structural integrity.

RFID Inventory Control

• Reduced product inventory cycle time.• Reduced number of touches on each product by 2 touches.• Eliminated setting up a load prior to shipment.• Scanner hard wired to forklift eliminating the use of handheld

scanners.• Notifies forklift operator if the wrong product is selected.• Notifies forklift operator if the product is placed in the wrong

location.• Reduces the time and increases efficiency of cycle counts.

RFID Inventory Control – Pre Installation

RFID Inventory Control – Post Installation

RFID Inventory Control

• Typical Product Cycle

Product

Product Produced

and Labeled

Forklift Scans

Product

Forklift Stores Item

Forklift Removes Item from

Storage to Ship

0 0

Product Scanned out of Inventory

RFID Inventory Control

• Inventory Cycle Screen• Onboard screen provides the

following information to the operator.

• Product Information• Roll Number• Storage Location

• Eliminated the use of handheld scanners.

• Provides proper storage location of product

Keytroller 601

• Keyless Keypad Ignition• Automation of Daily Forklift Inspection• Efficiency Tracking• Operator Accountability• Seat Belt Usage• Training Monitor• Machine Monitor• Lockout Enabled

Keytroller 601

• Keyless Keypad Ignition Features• Keypad eliminates the use of ignition keys• Driver inputs unique access code to enable vehicle

• Identifies operator using the forklift.• Prevents untrained/unauthorized personnel from operating lifts.

• Operator selects start button to start the engine.• Works with all types of engines including diesel.

• Operator selects stop button to stop the engine

START

STOP

Keytroller 601

• Automation of Forklift Inspection• Program in scheduled inspections• First operator to start the forklift is prompted to complete the inspection.• Failed items prevent truck from operating• Failed critical items require supervisor input

Keytroller 601

• Efficiency Tracking

• Loaded vs Unloaded Time Tracking (Hydraulic Sensor Necessary)• Calculates the amount of time the truck spends loaded vs unloaded

• Motor Efficiency (Speed Sensor Necessary)• Time spent idling• Time spend driving

Keytroller 601

• Operator Accountability

• Shock Sensor Operation• Triggers impact event• Records operator and time/date of event• Activates audible impact alarm• Disables forklift after 10 seconds• Requires supervisor to input reset access code

• Optional Speed Sensor Monitor/Limit Speed

Keytroller 601

• Operator Seatbelt Usage

• High Visibility Seatbelt• Orange seatbelts are easier to see

• Optional Seatbelt Sensor• Prevents operation of the forklift without a seatbelt• Ensures seatbelt is fastened• Does not prevent fastening seatbelt behind the back

Keytroller 601

• Training Monitor• Allows the input of scheduled expiration dates.• Ensures that only trained/authorized operators operate forklifts.• Allows the ability to disable a single operator.

Keytroller 601

• Machine Monitor• Monitors Critical Machine Components

• Engine Management• Low Oil Pressure• High Engine Temperature• Overload• Seatbelt Use• Seat

Keytroller 601

• Lockout Enabled• Supervisors and mechanics can electronically

lockout out a specific Forklift until repairs are complete.

• Prevents communication errors• Eliminates the use of forklifts that require

service.