Ensuring the safety of employees working in warehouses, distribution centers, and manufacturing operations is a top priority. To reduce safety risks, many operations use personal protective equipment (PPE) and physical barriers to separate humans from potential hazards. Despite efforts to establish procedures and implement measures aimed at minimizing human error, however, accidents still happen. Today, active protective guarding technologies are increasingly available to supplement traditional, passive solutions.

That was the crux of the Protective Guarding Manufacturers Association’s (ProGMA) MODEX 2024 educational session, “Evolution of Safety.” Presenter Mikael Carlsson, Head of Marketing, Business Development, and Mergers and Acquisitions at ProGMA member Troax, overviewed the continued advances in active protective guarding technologies over the past few years.

Human Error and Forklifts Pose Dangers

One of the persistent challenges in safety is the unpredictability of human behavior, explained Carlsson. In a typical warehouse, numerous safety hazards exist.

“These range from forklifts and unattended objects to non-compliance with PPE usage. The reality is that human beings do not always identify and react to these hazards consistently,” he said.

Forklift-related accidents are a major concern. Carlsson walked through several key statistics from the Occupational Health and Safety Administration (OSHA). These include:

• Approximately 100,000 forklift incidents occur annually in the U.S.
• Of these forklift incidents, 35,000 are serious accidents with significant financial and human costs.
• An estimated 90% of all forklifts will be involved in an accident during their operational lifetime.

“Key factors contributing to forklift accidents include travelling at excessive speed or with the load elevated. Improper turning, braking, backing, and acceleration are also problems. So too are overloading and poor communication,” Carlsson said. “Narrow aisles, crowded spaces, and poor lighting further exacerbate the risks.”

Evolving from Passive to Active Protective Guarding Technologies

“To try to reduce the risk of a forklift hitting a pedestrian, companies install barriers. These barriers physically keep employees away from the dangers,” continued Carlsson. “Examples include guardrails, bollards, fencing, cages, and other static, fixed barriers.”

In recent years, safety technology has seen significant advancements. Increasing environmental, health, and safety (EHS) inspections, along with software analytics, have been integral to identifying and addressing core safety issues. Also, more active protective guarding technologies have become available.

These solutions “work to detect and respond to potential hazards in real-time,” he said. “They alert employees to dangerous situations and prevent accidents, even in areas where it isn’t possible to place a barrier.”

Proactive Safety Solutions Explored

Among the solutions Carlsson featured in his presentation are wearables, radars, and sensors. These active protective guarding technologies leverage data and predictive analytics to anticipate and prevent accidents, he said. Among the solutions he discussed were:

Real-Time Monitoring and Alerts

Projectors and visual alert systems warn personnel of immediate dangers. These systems can dynamically manage safety and only activate alerts when necessary. “This can prevent desensitization to constant warning alarms and noise,” Carlsson said.

Advanced Collision Avoidance

New collision avoidance systems allow forklifts to detect and respond to other forklifts and pedestrians in their vicinity, reducing the likelihood of accidents. These systems can manage speed (faster or slower) and prevent forklifts from entering hazardous areas.

Analytics and Continuous Improvement

The integration of analytics and artificial intelligence (AI) provides valuable insights into safety performance. By analyzing data from various safety systems, businesses can identify trends and pinpoint high-risk areas. They can also make informed decisions to enhance safety protocols and warehouse layouts.

Ultimately, to achieve optimal safety, businesses must adopt a comprehensive approach, concluded Carlsson. “Essential elements include procedures, audits, PPE, barriers, software, and advanced solutions. Continuous monitoring, data analysis, and the adoption of active protective guarding technologies will also reduce accidents and improve safety,” he said.

More Safety Recommendations from ProGMA

The members of ProGMA are available to advise on both passive and active protective guarding technologies. They offer a list of Frequently Asked Questions (FAQs), a Protective Guarding Search Tool, and a Protective Guarding Checklist. These free resources can help ensure compliance and safety throughout key facility areas. Visit ProGMA’s website for more information.