Hi Jeff
We fitted our Active Collision Avoidance System (ACAS) to 3 tonne Doosan Trucks at a brick manufacturing plant that suffered the same problem. If you would like more information please contact Transmon Engineering UK and ask for Steve or Pete we may just have the solution you are looking for. I take it most of the impacts are the drivers reversing into structures or the counterweight swinging into objects when reversing. www[dot]transmon[dot]co[dot]uk

You can have 1 column in a warehouse and 1forklift in the same warehouse and some fool will hit it. the forklift hits the column or the column hits the forklift. This goes back to operator attitude about safety. Most unions I have been around have supported safety issues brought up if the operators just do not seem to get it. You can repair iron and steel a lot faster and with a lot less pain than flesh and blood. Most column accidents usually have a medical condition I call crainal rectus, other wise known as head up your axx syndrome.

I had started working on AGVs at my current company but after hearing about all the horror tales of forklift accidents decided to make safety priority number 1. We recently came out with a neat solution to automatically detect obstacles using camera and laser sensing to slow down and stop the lift automatically.

Video: www[dot]siera[dot]ai/safetyvideos

Would love to get what you folks think of using something like this?

Good to hear this... Thanks for the information..

Hello my name is jared. I work at a Walmart DC. 2 weeks ago I was involved in a accident at work. I was driving on a concrete dock on the refrigerated side of the warehouse. A associate was operating a floor scrubbing room on machine. They use them all the time to clean the floors. This associate was spraying g water on the floor next to the machine which is not standard practise. The machine is filled with water and cleaning solutions. Normally they spray directly in there path so the light water left behind is already mostly cleaned and free of the cleaning agent. As the machine *** up water as it goes.
I was attempting to go around the machine as it was cleaning directly I front of the doors to access the dry non refrigerated side of the warehouse. Apm noticing the solid puddle of water/cleaner I engaged the brakes but since this was a uncommon hazard I didn't not have to to stop I slid across the dock at least 20 feet. I was able to maintain direction but I did contact a metal pole next to the door. The impact was so minimal that there was a barley noticable paint transfer and no gouging or denting of eaither the equipment or the pole. The floor had no signs indicating it was wet. It was visually wet but no actual signage where up. I am fighting for my job AMD wondering I'd there is any regulations I can bring to my defence. I was given the determination of reckless driving. I reacted to the best of my abilities when I noticed it was slippery/ soapy water vs a normal wet floor. I have work at this location and operated highlight forklifts for 10+ years. I have never encountered a wet floor with cleaner that wasnt immediately being sucked up but rather sprayed to soak.

You just cannot hire an idiot cheap enough.

This post was started in 2010. By now the OP has either:
1.) Solved his issue
2.) Been fired for letting the drivers manage the business vs. the company management/supervisors

To minimize damages and Safety issues in tight production areas you should go to Tugger carts to move your material. Even AGV's if you have the money. Lifts should be in Shipping, Reciving and Warehouse.

You can use Fork view camera to prevent the accidents in the Warehouses and storage houses

Informative

I may be too late, but it sounds like you need an alert system. Check out www.zonesafe.net. They use RID technology for accurate measurements and is sure to ensure that you avoid collisions. :)

If your teenager, for no good reason, ran your car into a tree, would you then accept that the driver is responsible for their actions?
To drive a forklift into a column is a complete lack of responsibility. Your drivers are driving machines that weigh tons. These are giant weapons. The drivers need to be accountable for their actions. I would allow one such mishap (with retraining to follow).
A repeat incident would have the driver owning a different type of job. This isn't "bumper cars".

I think companies have really just got to come down harder on reckless operators.
The problem with idiot proofing everything is they just invent a 'a better idiot'.

These sort of accidents are usually a result of distraction or excessive speed. I'm not saying in any way this is the case in this instance but I've had a few sites where it's the employer who needed to have a long hard look at itself, it's easy to blame the operators when the company has an ethos of 'work harder, faster NOW!' or a company that didn't really care about it employees so the same care is paid in return by staff.

I think the forklifts and the related operations through forklifts are really dependent on the drivers and to be safe and avoid such accidents the only way is to have proper driving classes and loading unloading training. there must be kept criteria on which the whole process or hiring of the drivers shall be based on.

My system prevent accidents every day in work places !!
I know that I have the best solution to prevent accidents.
It's Visual with flashing lights and an alarm system every time the Forklifts approaching a blind spot or around the corner.
Please contact me I know I can help you.
Sigal

I agree with many of the previous posts. Be sure to document: your training procedures (including your hands-on evaluation process), document your company forklift policies and disciplinary action that will occur for any and all incidents, accidents or near misses.

If and when there are changes or updates in policy and procedures that occur have a refresher class for all operators. Create documentation each must sign and agree that they are aware of the new company policy. I also like the idea of utilizing a product like Shockwatch. Unfortunately, it does not do anything to prevent an incident, accident or near miss. However, it could prove beneficial with disciplinary action if it were to occur.

It would be hard for the employee to dispute any disciplinary action since the operator using the piece of equipment would be signed in to the system when it occurred. Also, peer pressure can do wonders, especially if after the impact, a supervisor has to come out and reset the truck.

Safety in the warehouses are a priority for all the warehouse managers. All the necessary training as well as safety equipment still sometimes fails in the face of certain accidents. However having a proper security and surveillance systems can help avert avoidable incidents by letting the staff know of any faulty equipment before hand.

As well as painting the potential hit items as you have done, if it's on cement paint a yellow line on the ground half a meter from the object. It stands out if people are over that line and close to the object. Also if they do do this, the paint in that section will wear off faster and you can see how close they are cutting the corner.

EVERY operator should be held accountable for the operation of his lift and any accidents he has on it.
ways to help keep him in check?
slow the lifts down, set the max speed to a slower rate if it is adjustable on the machine, if not then as has been suggested, install a speed limiter on it.
Putting a wireless collison system or shockwatch impact manager is kinda redundant being that he is trying to prevent the collision before it happens. But none the less if the operator thinks he is being watched or recorded by the device on the lift then he will be more conscientious of how he drives and have less incidents.

As far as wireless speed managers how well do they actually work? I have not had any exposure to these yet. How much do they cost and how accurate and dependable are they?
From a sales standpoint i'm sure i'll hear the usually hype but i want to know the real deal on them from warranty returns, failure rates, etc.

in the end i think usually what works best is to slow the lifts down.

Hi Jeff. Sounds more like an awareness and attitude situation here. In Alberta, as a Trainer, there are four factions to my safety course. Skill, Knowledge, Awareness and Attitude. Awareness and Attitude are the most important functions I teach in safety. If these two are lacking then the rest doesn't matter. Teaching awareness and attitude by consequences of actions and real life accident involvement, my students realize they do not drive from the seat of a forklift, but rather from the perspective of the tips of the forks and the rear of the forklift. We have been very successful in this training method and if this is something that might help you, by all means drop me a line.
Cheers