Overview
A UK-based manufacturing and warehouse operation introduced a combined facility with Very Narrow Aisle (VNA) forklift operations.
During early use, it became clear that pedestrians needed to occasionally enter or cross active forklift zones to access work areas.
This created two key risks:
- Pedestrians entering restricted VNA aisles
- Pedestrian crossings across main forklift routes
Static signage alone was not sufficient to clearly manage right-of-way in these dynamic environments.
Solution
An automated projection-based safety system was installed to provide clear, real-time visual guidance.
VNA Aisle Safety Signage
- Default projection: “No Pedestrians”
- Manual override switches to: “No Forklifts” when access is required
- Ensures clear, visible right-of-way at all times
Automated Crossing System
- Projected pedestrian crossing with stop indicators
- High-visibility, dynamic warnings for both pedestrians and operators
- Designed to remain effective in busy, high-wear environments
Implementation
Installed within the warehouse using the client’s contractors, with commissioning support.
- Projection units positioned above key zones
- Visibility calibrated for operational lighting
- Manual override integrated into workflow
- Fully tested with site teams before handover
Outcome
The system introduced a clear, consistent hierarchy between pedestrians and forklifts.
- Improved visibility at key risk points
- Clearer right-of-way guidance
- Reduced reliance on static signage and human judgement alone
Early feedback indicates improved awareness and more controlled interactions across the site.
Impact on Operations
- Supports safer movement without slowing operations
- Reinforces behaviour at the point of risk
- Remains visible regardless of floor wear or conditions
- Adapts instantly to changing access requirements
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