What makes today's forklifts safer to operate than ever before? Experts name some of the most important improvements of the past few years and explain why forklifts of the future are likely to be even safer.
Contributing Editor Toby Gooley is a writer and editor specializing in supply chain, logistics, and material handling, and a lecturer at MIT's Center for Transportation & Logistics. She previously was Senior Editor at DC VELOCITY and Editor of DCV's sister publication, CSCMP's Supply Chain Quarterly. Prior to joining AGiLE Business Media in 2007, she spent 20 years at Logistics Management magazine as Managing Editor and Senior Editor covering international trade and transportation. Prior to that she was an export traffic manager for 10 years. She holds a B.A. in Asian Studies from Cornell University.
If a forklift driver who retired 20 years ago came back to work in a warehouse or DC today, he or she would be surprised by how much lift trucks have changed. Just as in the auto industry, vehicle design, fuel efficiency, and on-board technology have all improved dramatically in just the last few years.
One area that has seen some of the biggest improvements is safety. Manufacturers of forklifts and accessories have devoted a great deal of effort to developing innovative products that help operators use lift trucks more safely. And whether safety features are integral to the lift truck's design or after-sale add-ons, the objective is the same: fewer accidents and a safer workplace for operators and pedestrians alike.
As part of our special coverage for National Forklift Safety Day 2016, we asked forklift manufacturers to identify some of the most important safety improvements of the past few years. Here, in no particular order, are their top picks:
Operator presence systems. "Operator presence systems" prevent forklifts from traveling without a driver seated properly at the controls. According to Mitsubishi Caterpillar Forklift America Inc. (MCFA), which says it was the first lift truck manufacturer to introduce them to the North American market, these systems stop certain hydraulic and transmission functions when the operator does not fasten the seat belt during operation or leaves the normal operating position without activating the parking brake.
One example is UniCarriers Americas' version, which halts the truck by shifting it into neutral and locks out hydraulic functions if the operator is not seated, explains product manager Tony Kordes. The lift and tilt lock will also stop mast operation when the driver leaves the seat, he says. The basic functionality of other manufacturers' systems is similar; all include a warning lamp and/or an audible signal to alert drivers to their errors.
Operator presence systems typically rely on a sensor inside the seat to signal a controller to prevent the truck from moving and/or handling loads when needed. Another approach that's designed for standup trucks involves two light sensors that span the entry to the operator compartment. If a sensor is blocked, indicating that the driver is not correctly positioned or that an object is in the operator compartment, the truck will not travel, says Justin Byma, product manager for very-narrow-aisle products at The Raymond Corp.
Improved visibility. When an operator can't clearly see what's in front of, behind, above, and adjacent to a lift truck, accidents are bound to happen. Many manufacturers have therefore given trucks of all types sleeker profiles and thinner frames with wider openings around the cabin to improve sight lines in all directions.
Some of the biggest visibility gains in the past few years have come from mast designs that make it easier to see through and around them yet maintain strength and stability. This has been a high priority for many OEMs. Just one example is Crown Equipment Corp.'s MonoLift mast for two of its reach truck series. The mast offers better visibility because it is offset seven inches to the left of the operator and gets narrower the higher it goes, explains Jim Gaskell, director of global technology business development. Another example is the reach carriage on Crown's RM series, which is shaped to create a large window at eye level to provide the operator with a better view of the fork tips and load, he says.
Visibility-enhancing attachments and accessories, such as mirrors, brightly painted forks, and fork-mounted video cameras, have also made a notable contribution to forklift safety. One increasingly popular option, says Chuck Leone, vice president of Hyundai Forklift, is a backup camera. Similar to those available in recent-model cars, forklift cameras improve visibility behind the vehicle. Operators still need to turn around and keep watch on what's going on behind and around them, of course, but the cameras expand their view from the floor up, allowing them to clearly see pedestrians and objects that may be below eye level.
Better visibility is not just for the operator, by the way. Making pedestrians more aware of the presence and travel direction of nearby forklifts is also important. One of the most effective visibility tools in recent years is the "blue light" accessory, says Max Vome, health, safety, and environment manager at Kion North America Corp., parent of Linde and Baoli brand forklifts. This simple device attaches to the lift truck's frame and projects a bright, highly visible blue light onto the floor behind, in front of, or alongside a moving forklift, as appropriate for the situation. The light provides an early warning—by projecting beyond the end of an aisle, for example, so pedestrians and other lift trucks know that a truck is coming even though they may not be able to see it yet.
Lift truck telematics. Telematics (also known as telemetry) refers to the wireless transmission of data to or from a mobile asset. Telematics for forklifts and the technologies used for collecting, sharing, and analyzing lift truck-related data are becoming increasingly sophisticated. Some systems are offered by independent providers, such as I.D. Systems and Total Trax, while others are available through forklift manufacturers, which have either developed their own software or partnered with an independent developer.
Lift truck telematics systems generate easy-to-access metrics and can be highly effective tools for improving operator safety, say the experts at Toyota. Depending on the application, these systems can help fleet managers monitor operators' driving habits, track impacts, and collect and store OSHA-required information, among other capabilities. They also analyze the data, which helps companies identify individual operators who need additional training.
For example, telemetry systems equipped with operator-checklist capabilities allow operators to easily perform OSHA-required preshift inspections, identifying possible maintenance issues and potentially locking down units to prevent unsafe operation, says Jay Costello, director, dealer marketing, for Yale Materials Handling Corp. (Yale is part of Hyster-Yale Materials Handling Inc., which also markets products under the Hyster brand name.) Units equipped with an identification-card reader can limit access so only appropriately trained workers are able to operate specific equipment. Telemetry systems can also alert operators and managers when certifications are near expiration, helping to ensure refresher training is provided on a timely basis, he adds.
Impact monitoring is one of the most valuable safety enhancements in fleet telematics systems. Operators understand that impacts can be easily audited to determine frequency, amplitude, and, ultimately, responsibility. As a result, truck damage and injuries from impacts generally decrease when a fleet management system is implemented, says Gaskell.
Stability enhancements. Lift truck makers have made a variety of design changes to help prevent tipping when loads are elevated. Improvements in the design and placement of outriggers, counterbalance weights, and (in high-lift trucks) operator compartments are just some of the features that have contributed to better stability.
Toyota says it has paid special attention to stability with its unique System of Active Stability (SAS) and Active Mast Control (AMC) technologies for sit-down counterbalanced trucks. When the SAS detects factors that lead to potential lateral instability, it locks a hydraulic cylinder on the rear steer axle, changing the forklift's stability footprint from a triangular shape to rectangular to decrease the likelihood of a tipover. The AMC system senses factors like load weight and mast height that lead to longitudinal instability. If needed, it will automatically override the operator's manual control and limit the forward tilt as well as the reverse tilt speed to reduce the chance of spilling a load or tipping the forklift.
THE FUTURE OF FORKLIFT SAFETY
While the industry has made great strides in forklift safety in the past few years, the OEMs are confident there are more improvements to come. Some will be inspired by developments outside the material handling industry. Hyundai's Chuck Leone, for one, foresees lift truck makers adopting more safety-enhancing technologies from the automotive and trucking industries. As technologies like laser-guided collision-avoidance systems are perfected and become more common, forklift OEMs will adapt them for material handling applications, he predicts.
Justin Byma of Raymond says he expects a surge of interactive training tools that will help to improve forklift safety in the future. These tools will be based on simulation and gaming technology, and will help a new generation of operators learn how to properly operate material handling equipment in a virtual environment, he says.
Effective application of technology will be fundamental to further progress on safety, forklift executives agree. For example, Bob Hasenstab, general product manager at Kion North America Corp., forecasts that future improvements are likely to come from such developments as automated forklifts with object-detecting sensors, weight- and height-sensing devices to ensure proper lifting, noise and vibration reduction to reduce fatigue levels, and automatic speed reduction to adjust to load weight and curves.
The kind of programmable controls and semi-automation described by Hasenstab were at the top of several OEMs' lists for both current and future improvements. While such capabilities are available now, they are not yet in widespread use, and vendors will continue to introduce new products and improvements in this area.
MCFA, whose Jungheinrich brand offers the Warehouse Navigation semi-automation system for remotely controlling lift truck operation, notes that lift trucks are becoming sophisticated "computers on wheels" that allow customers to customize and program many aspects of the forklift's operation to meet particular requirements, thereby helping to reduce risks stemming from operators' errors in judgment. For example, using location signals from radio-frequency identification (RFID) tags, Jungheinrich's system can control a lift truck's acceleration, travel speeds, lift heights, stops, and avoidance of overhead objects.
Yale recently joined the field with its A-Ware control solution, which also uses RFID sensing to enforce travel speed, acceleration, and lift restrictions. The company says its system can also adjust to the nuances of each aisle, identifying high-traffic areas and automatically detecting dead-ends to reduce the risk of collisions.
IT ALL COMES DOWN TO PEOPLE
Equipment design and technology are extremely important tools for improving safety, but they can—and should—only go so far. It's important that operators are not lulled into expecting the forklift to do everything for them, or believing that the technology takes the responsibility for safe operation off their shoulders, says Crown's Gaskell.
That was something every lift truck OEM we polled agreed on, and which many emphasized. Tony Kordes of UniCarriers spoke for all of them when he said, "Manufacturers design with the standards in mind and create the best equipment to encourage proper use and protect operators in case of accidents, but nothing can be designed into a lift truck to make it perform safely with an operator who doesn't use it that way. So the absolute best way to improve operator and warehouse safety is to train every operator properly and continually refresh and reinforce those practices. Operators still must take responsibility for their actions."
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, including composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The British logistics robot vendor Dexory this week said it has raised $80 million in venture funding to support an expansion of its artificial intelligence (AI) powered features, grow its global team, and accelerate the deployment of its autonomous robots.
A “significant focus” continues to be on expanding across the U.S. market, where Dexory is live with customers in seven states and last month opened a U.S. headquarters in Nashville. The Series B will also enhance development and production facilities at its UK headquarters, the firm said.
The “series B” funding round was led by DTCP, with participation from Latitude Ventures, Wave-X and Bootstrap Europe, along with existing investors Atomico, Lakestar, Capnamic, and several angels from the logistics industry. With the close of the round, Dexory has now raised $120 million over the past three years.
Dexory says its product, DexoryView, provides real-time visibility across warehouses of any size through its autonomous mobile robots and AI. The rolling bots use sensor and image data and continuous data collection to perform rapid warehouse scans and create digital twins of warehouse spaces, allowing for optimized performance and future scenario simulations.
Originally announced in September, the move will allow Deutsche Bahn to “fully focus on restructuring the rail infrastructure in Germany and providing climate-friendly passenger and freight transport operations in Germany and Europe,” Werner Gatzer, Chairman of the DB Supervisory Board, said in a release.
For its purchase price, DSV gains an organization with around 72,700 employees at over 1,850 locations. The new owner says it plans to investment around one billion euros in coming years to promote additional growth in German operations. Together, DSV and Schenker will have a combined workforce of approximately 147,000 employees in more than 90 countries, earning pro forma revenue of approximately $43.3 billion (based on 2023 numbers), DSV said.
After removing that unit, Deutsche Bahn retains its core business called the “Systemverbund Bahn,” which includes passenger transport activities in Germany, rail freight activities, operational service units, and railroad infrastructure companies. The DB Group, headquartered in Berlin, employs around 340,000 people.
“We have set clear goals to structurally modernize Deutsche Bahn in the areas of infrastructure, operations and profitability and focus on the core business. The proceeds from the sale will significantly reduce DB’s debt and thus make an important contribution to the financial stability of the DB Group. At the same time, DB Schenker will gain a strong strategic owner in DSV,” Deutsche Bahn CEO Richard Lutz said in a release.
Transportation industry veteran Anne Reinke will become president & CEO of trade group the Intermodal Association of North America (IANA) at the end of the year, stepping into the position from her previous post leading third party logistics (3PL) trade group the Transportation Intermediaries Association (TIA), both organizations said today.
Meanwhile, TIA today announced that insider Christopher Burroughs would fill Reinke’s shoes as president & CEO. Burroughs has been with TIA for 13 years, most recently as its vice president of Government Affairs for the past six years, during which time he oversaw all legislative and regulatory efforts before Congress and the federal agencies.
Before her four years leading TIA, Reinke spent two years as Deputy Assistant Secretary with the U.S. Department of Transportation and 16 years with CSX Corporation.
Serious inland flooding and widespread power outages are likely to sweep across Florida and other Southeast states in coming days with the arrival of Hurricane Helene, which is now predicted to make landfall Thursday evening along Florida’s northwest coast as a major hurricane, according to the National Oceanic and Atmospheric Administration (NOAA).
While the most catastrophic landfall impact is expected in the sparsely-population Big Bend area of Florida, it’s not only sea-front cities that are at risk. Since Helene is an “unusually large storm,” its flooding, rainfall, and high winds won’t be limited only to the Gulf Coast, but are expected to travel hundreds of miles inland, the weather service said. Heavy rainfall is expected to begin in the region even before the storm comes ashore, and the wet conditions will continue to move northward into the southern Appalachians region through Friday, dumping storm total rainfall amounts of up to 18 inches. Specifically, the major flood risk includes the urban areas around Tallahassee, metro Atlanta, and western North Carolina.
In addition to its human toll, the storm could exert serious business impacts, according to the supply chain mapping and monitoring firm Resilinc. Those will be largely triggered by significant flooding, which could halt oil operations, force mandatory evacuations, restrict ports, and disrupt air traffic.
While the storm’s track is currently forecast to miss the critical ports of Miami and New Orleans, it could still hurt operations throughout the Southeast agricultural belt, which produces products like soybeans, cotton, peanuts, corn, and tobacco, according to Everstream Analytics.
That widespread footprint could also hinder supply chain and logistics flows along stretches of interstate highways I-10 and I-75 and on regional rail lines operated by Norfolk Southern and CSX. And Hurricane Helene could also likely impact business operations by unleashing power outages, deep flooding, and wind damage in northern Florida portions of Georgia, Everstream Analytics said.
Before the storm had even touched Florida soil, recovery efforts were already being launched by humanitarian aid group the American Logistics Aid Network (ALAN). In a statement on Wednesday, the group said it is urging residents in the storm's path across the Southeast to heed evacuation notices and safety advisories, and reminding members of the logistics community that their post-storm help could be needed soon. The group will continue to update its Disaster Micro-Site with Hurricane Helene resources and with requests for donated logistics assistance, most of which will start arriving within 24 to 72 hours after the storm’s initial landfall, ALAN said.