Enhancing Forklift Safety: SEEN Safety Trial “Successfully Changed Behaviors and Attitudes”

After a successful trial of SEEN’s forklift pedestrian alert system, a major U.S. building products manufacturer is rolling out SEEN Safety sensors across its facility. Here's why.

Despite previous close calls and minor incidents, the true extent of pedestrian-vehicle risks was difficult to assess without concrete data. To gain a clearer picture, the facility launched a 4-week trial of SEEN’s forklift safety system with the following objectives:

• Increase overall safety awareness.
• Modify behaviors around mobile equipment.
• Gain support from all participants and leadership.
• Capture evidence of unreported high-risk pedestrian-vehicle interactions.

SEEN’s system not only alerted forklift drivers to pedestrian proximity but also provided clear, objective data on each incident, helping the safety team fully understand and address these critical risks.

Using SEEN’s advanced IRIS 860 sensors, the system detected the retroreflective tape on high-visibility PPE and triggered alerts when pedestrians were within a customizable zone behind reversing forklifts.

Trial Insights and Results

From day one, the system identified a significant number of pedestrian-vehicle detections. The facility's existing mandatory high-visibility PPE ensured reliable detection, even in challenging conditions. Over the course of the trial, involving just two forklifts, more than 100 close proximity pedestrian interactions were recorded—averaging around 3.5 incidents per day. Over 50% of these interactions occurred within 6 feet of a reversing machine, and about one-third were closer than 4 feet.

The facility's Safety Manager commented, “The photos and videos allowed us to fully grasp what was happening on the floor. While we had reports of near-misses, the ability to analyze these situations with concrete data and images was truly eye-opening.”

Key Findings:

• Immediate Safety Improvements: Audible alerts prompted drivers to look and brake, reducing risky situations in real-time.
• Decreased High-Risk Proximity: The frequency of close pedestrian interactions dropped after health and safety interventions and targeted training.
• Previously Unseen Risks Identified: The system quantified and visualized pedestrian-vehicle interaction risks that had previously gone undetected.
• High-Visibility PPE Enabled Reliable Detection: The site’s existing PPE protocols ensured accurate and consistent detection in diverse conditions.

A Proactive Approach to Safety Culture

By leveraging the detailed detection data in SEEN Insight, the Safety Manager implemented a proactive safety strategy, further highlighting the system's value. Initiatives included:

• Regularly reviewing detection data with the team.
• Using detection videos in toolbox talks and individual coaching sessions.
• Sharing key findings with site management.
• Introducing a reward system for safe behaviors identified by the system.
• Addressing safety concerns through oversight and constructive discussions.

“This trial successfully changed behaviors and attitudes,” said the Safety Manager. “There’s now general acceptance that a detection system is beneficial, with clear evidence of a return on investment.”

With these results, SEEN’s safety system is now being rolled out across the entire facility.

Contact us today to learn how the SEEN system can enhance safety at your workplace.