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Forklift Traffic Management — FAQ
What is forklift traffic management?
A structured approach to separate or control interactions between forklifts and pedestrians, set right-of-way rules, manage speed, improve visibility, and reduce collision risk across the warehouse.
What are the core controls?
Defined routes and one-way aisles, marked crossings, speed limits, mirrors/lighting, physical barriers, horn/blue-light policies, stop/hand-signal rules, and access control to high-risk zones.
Who has right-of-way?
Policies should give pedestrians priority at designated crossings and walkways. Operators slow, sound horn where required, and yield before proceeding when line-of-sight is limited.
How do we set speed limits?
Use layout, congestion, visibility, and stopping distance. Enforce via signage, limiters/telematics, and audits—slower at intersections, docks, and congested picking.
What makes a good crossing?
High-contrast markings, stop lines, mirrors or warning lights, pedestrian gates/chicanes, and good sightlines placed away from blind corners and rack ends.
Blue lights and alarms?
Helpful as additional warnings when standardized and verified in real lighting/noise; avoid alarm fatigue.
How often to review routes?
After layout changes, incidents/near-miss trends, seasonal peaks, or at least annually, with operators and pedestrians involved.
What training is needed?
Licensing on truck type, practical route rules, right-of-way, speed control, load handling, stability basics, and emergency procedures.
Reducing blind-corner risks?
Convex mirrors, corner guards, stop lines, horn policy, low speed, one-way aisles or guarding, and removing obstructions.
Which metrics matter?
Leading: near-misses, harsh braking, speeding alerts, audit pass rate. Lagging: collisions, damages, injuries. Track time-to-close unsafe conditions.
PPE for pedestrians?
High-visibility garments and safety shoes are common; add hearing protection where noise levels require.
Integrating with WMS/telematics?
Use task interleaving, travel rules, geo-fences, speed profiles, staged waves, and on-screen prompts to reduce congestion and reinforce rules.
One-way aisles—yes or no?
Where space allows, one-way aisles cut head-on conflicts; mark with floor arrows and end-cap signs, then audit.
Mixed fleets guidance?
Define zones by truck type, separate pedestrian-operated equipment where feasible, and tune speed profiles/passing rules.
Seatbelt policy?
Wear seatbelts/restraints when fitted; verify in start-up checks; coach violations immediately.
Evidence to keep?
Route maps, risk assessments, training/licensing, audits, telematics summaries, incidents, and corrective actions with verification dates.
Avoiding alarm fatigue?
Standardize where/when to use alarms, remove redundant alerts, and review effectiveness with operators/pedestrians.
Visitors/contractors?
Escort and brief, provide high-vis, restrict to walkways, and record induction before entering live traffic areas.
When to stop operations?
If an immediate risk exists (blocked exit, failed brake, uncontrolled spill, racking damage, visibility loss), stop and escalate per emergency procedures.
Note: this is general guidance; always follow your local laws and company policies.