Forklift Hazard & Pedestrian Proximity Prevention in Warehouses
A 500,000 sq. ft. logistics distribution center operating 40 industrial forklifts alongside 150 warehouse order pickers in high-density rack aisles.
Run on Arjuna · Plant Operations & Safety
The challenge
Blind intersections at aisle ends caused frequent near-miss incidents and dangerous forklift-pedestrian collisions.
Wearable RFID tag proximity systems were unreliable because workers forgot to charge or wear their badges.
Warehouse managers lacked objective data on high-risk collision blind spots across the facility.
How Arjuna solves it
Overhead Aisle Camera Video Stream Analysis
Arjuna processes video from overhead aisle CCTV cameras, tracking real-time 3D positions of forklifts and workers.
Dynamic Proximity Hazard Vector Calculation
Calculates real-time approach speeds and trajectory vectors, detecting blind-corner collision paths 3 seconds before impact.
Aisle Warning LED & Audio Interlocking
Flashes high-visibility overhead warning LEDs and sounds directional audio alarms at specific aisle intersections when collision paths are detected.
Forklift Speed Zone Verification
Detects speeding forklifts in pedestrian-only zones, logging operator IDs for safety coaching.
Near-Miss Spatial Heatmap Generation
Generates visual facility heatmaps identifying high-risk collision zones to optimize warehouse traffic routing.
The outcome
- reduction in forklift-pedestrian near-miss incidents
- 0%reduction in forklift-pedestrian near-miss incidents
- replaced wearable RFID tags
- 0%replaced wearable RFID tags
94% reduction in forklift-pedestrian near-miss incidents across the distribution center.
Zero forklift collision injuries achieved since deployment.
Replaced wearable RFID tags with 100% camera-based, zero-maintenance pedestrian safety coverage.
Representative scenario: a modelled industry situation showing how this accelerator applies. Figures are projections, not a named client result.
Capabilities used
Every accelerator is assembled from the same capability layer, so a workflow you adopt here shares its foundation with the rest of the portfolio.
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