Categories
News Nicht kategorisiert

Safety in the warehouse

Safety in the warehouse

The topic of safety in warehouse traffic with forklift trucks is regularly on the to-do list of business owners and plant managers. The protection of employees is the top priority.

When it comes to forklift truck safety, many people first think of the dangers for the drivers. However, many other people work in a warehouse, often in the immediate vicinity of forklift trucks. They are travelling on foot, pushing roll containers or pulling hand pallet trucks and are exposed to a high risk of accidents: Because if they get in the way of a forklift unnoticed, there is only one winner. The annual report on accidents at work published by the DGUV (German Social Accident Insurance) shows that the risk of accidents when working around forklift trucks should not be underestimated. In 2024, forklift trucks were the leading cause of reportable accidents with almost 6,000 cases, closely followed by non-motorised tiller trucks, i.e. manual hand pallet trucks and high-lift trucks.

In the RIDDOR* accident reports of recent years, it was noted that a second person was involved in over 40 per cent of accidents involving forklift trucks. Of these, over 60 per cent were pedestrians – employees working nearby – and around 20 per cent other people (inspectors, passers-by) and 15 per cent delivery drivers.

These accidents often have devastating outcomes with serious health consequences for those affected and for the company itself: They often result in reputationally damaging investigations, costly compensation claims, legal proceedings and fines. Every company has a duty to ensure the safety of its employees and to minimise all risks as far as possible. Forklift driver training and regular instruction are therefore a must for every company with industrial trucks in use. At the same time, it is equally important to ensure the safety of those who work unprotected in the vicinity of free-moving forklift trucks.

Mitsubishi Axia EM
Generated with AI

Tips for more protection for pedestrians

Separation is the safest means

The smartest advice for pedestrians in the warehouse is: keep your distance from forklift trucks. Do not enter areas where forklift trucks are manoeuvring and do not enter areas that are closed to pedestrians – not even as a “shortcut” under time pressure!

If pedestrians and forklift trucks are working in the same area, there should be designated walkways separated from other traffic. These should be protected by barriers and emphasised by markings.

Never be tempted to walk or work under a raised load – always keep a safe distance.

If a forklift truck is equipped with zone warning lights, you should not enter this area under any circumstances. The blue warning lights on the forklift truck mark the danger zone in front of the vehicle. Red marks the danger zones around the forklift truck.

Do not take any risks

Do not ride as a passenger on a forklift truck and never allow yourself to be lifted with the load or the forks.

Never attempt to stabilise a load that is sliding off the forks and do not try to act as an additional living counterweight. People are regularly killed trying to act as a counterweight.

Cautious approach

Always wear high-visibility waistcoats. It is much easier for pedestrians to recognise a forklift truck than it is for the forklift driver to see the pedestrian.

If a forklift truck approaches you, make absolutely sure that the driver has seen you. Only approach the forklift truck when it is stationary – and then only from the side.

Pedestrians need to be extra vigilant in areas where forklift trucks are travelling and working and watch out for blind spots as soon as they enter an aisle, turn a corner or walk through a doorway.

The most common causes of accidents involving forklift trucks

Inspections and daily maintenance neglected: Whether forklift truck or car – a vehicle that is not technically roadworthy is a danger for everyone involved.

Safety rules not observed: Forgetting to fasten the seat belt. Forklift left unattended with key so that unauthorised persons can drive it. Load securing forgotten. Bypassed the TOT man switch. Raced, tested the limits…

The forklift tips over: Due to their weight distribution, forklift trucks tend to tip over quickly. The risk increases enormously, especially when cornering and manoeuvring with a raised load.

Working in confined spaces: If the forklift truck is heavily loaded, visibility is often restricted and the stress factor is high. Under time pressure, work is hectic and there is an increased risk of overlooking pedestrians.

The loads are not distributed correctly: The transported goods must always be evenly distributed. Securing against slipping is essential. The higher the mast is extended, the more it can sway.

Modern safety systems in forklift trucks

Renowned forklift truck manufacturers have been investing in the safety features of their industrial trucks for years. Many new forklift trucks already have intelligent systems that warn drivers of dangerous situations or prevent them from arising in the first place. Examples include cornering control systems, person detection and distance sensors, automatic ramp stop, mast stabilisation systems, pin code key systems and much more.

*RIDDOR = Reporting of Injuries, Diseases and Dangerous Occurrences Regulations. The Reporting of Injuries, Diseases and Dangerous Occurrences Regulations is a legal requirement in England.

Categories
News Nicht kategorisiert

More than transporting, lifting and storing

More than transporting, lifting and storing

Efficient forklift use in practice

Effective is not automatically efficient

Effectiveness means achieving defined targets – such as high turnover rates or short throughput times. Efficiency goes one step further: it describes how much effort is required to achieve these goals.

An example from e-commerce:
A warehouse can turn over its entire inventory within 24 hours. If this target can even be achieved in 20 hours, this is undoubtedly effective. However, if an oversized fleet of forklift trucks, high labour costs, a lot of damage, frequent downtime or uncoordinated loading cycles have to be accepted, efficiency suffers – and ultimately profitability.

This shows that good performance alone is not enough. It must also be provided at a reasonable cost.

Not every forklift truck application needs optimisation

At the same time, it is important to remain realistic.
Not every company needs to analyse its forklift use down to the last detail. Anyone who uses one or two forklift trucks occasionally – for unloading pallets or storing materials, for example – uses the forklift truck primarily as a practical tool. In such cases, the benefits are obvious: time savings, relief for employees and greater safety.

© Mitsubishi EDIA EM FB14-20(C)N2T Series

The situation is different when forklifts are an integral part of the value chain.
For example, in beverage wholesaling with indoor storage, outdoor areas and additional event services. Here, forklifts, pallet trucks and drivers are an essential part of daily business. Precision, availability, safety and speed have a direct impact on costs and revenue. In such environments, it is worth taking a closer look.

When others achieve more with less effort

The desire for optimisation is often not driven by the company itself, but by comparison:
A competitor achieves similar handling figures, but works with fewer machines, fewer staff or lower costs. This is the latest point at which processes, vehicle fleets and operating times are scrutinised.

The first step is always an honest stocktaking:

  • How have routes, warehouse structure or types of goods changed?
  • How many hours are the forklifts actually in use?
  • Are there many empty runs or downtimes?
  • How are machines and loads handled in everyday life?
  • Do all vehicles fulfil the current safety requirements?

These questions can often still be answered “from the gut” in small fleets. However, this becomes increasingly difficult as the number of vehicles grows.

Data instead of gut feeling

The larger the fleet, the more complex the evaluation becomes.
Manual recording of operating times, driving behaviour or downtimes is hardly realistic in day-to-day business. It costs time, ties up staff and often only provides snapshots.

This is where telematics comes into play.

© Mitsubishi PREMIA EX PBR20-30N2 Series

Efficiency gains through telematics

Telematics systems record relevant data directly on the vehicle: usage, operating times, battery status, driving behaviour or load on the components. This information is analysed centrally and creates an objective basis for decision-making for the first time.

Typical questions can thus be clearly answered:

  • Which forklifts are heavily utilised – and which are hardly utilised at all?
  • Where do many empty journeys occur?
  • At what times do load peaks occur?
  • How do driving styles and utilisation differ between individual drivers?
  • When does maintenance make sense before failures occur?

This is particularly important for retailers:
Telematics does not replace experience – it supports it with facts.

The right machines for the right tasks

Efficient fleet management does not mean using as many vehicles as possible, but rather providing suitable vehicles for specific tasks.

A simple practical example:
A company uses telematics data to recognise that several electric forklift trucks with a high load capacity mainly travel short distances, rarely pick up loads and have long idle times. The analysis shows that some of these tasks could be better performed by low-platform trucks. Replacing machines not only reduces the vehicle fleet, but also the personnel and maintenance costs – with the same performance.

Such decisions can hardly be made on a sound basis without data. Telematics makes them comprehensible and economically justifiable.

Conclusion

Efficient forklift truck utilisation does not start with technology, but with an understanding of your own processes.
Telematics is not an end in itself, but a tool for creating transparency, recognising potential and making well-founded decisions. For dealers, this knowledge opens up one thing above all: the opportunity to provide customers with better advice – practical, comprehensible and based on real usage data.

Looking for equipment?

FORKLIFT - La red de distribuidores más grande de la industria

Comprar barato - ¡Vender más rápido!

¿Alguna pregunta?

Contáctanos directamente:

Ana Fischer


Country Manager Spain

+49 941-942794-24