Warehouse and factory transport safety

Forklift and Pedestrian Safety AI Video Analytics

AI video analytics for forklift lanes, pedestrian entry, restricted zones, blocked routes, wrong-way movement, and PPE rules in warehouses, factories, and logistics facilities.

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Forklift safety depends heavily on how people and vehicles share space. A useful camera rule starts with the route plan: where forklifts are allowed, where people may walk, where the paths cross, and where goods may stay during loading. The same video view can then be used to generate a reviewable event when a defined rule is broken.

Typical camera rules

Pedestrian entry into a forklift lane

The system can watch a marked forklift lane, blind corner, loading approach, or narrow aisle for people entering a controlled area. The region should exclude the adjacent pedestrian path. A short delay can avoid alerts from someone who only appears near the boundary.

Forklift entry into a controlled area

A forklift can be detected in a pedestrian route, office entrance, protected work area, or other restricted space. The site needs to identify time periods and loading tasks that allow an exception. Those details belong in the camera rule, not in a generic model name.

Route occupation and PPE events

Pallets, goods, and vehicles that block a narrow route can be handled as a stay-duration event. Helmet and vest rules can run separately where they are required. Keeping these events separate makes the review queue easier to understand.

Camera and acceptance conditions

The camera should show the forklift body, the person, and the relevant route boundary. Racking, pallets, suspended loads, sharp turns, and reversing create frequent occlusion. Test empty and loaded forklifts, turning, reversing, normal pedestrian passage, peak loading, and the highest-risk crossing. A normal 2D camera view does not provide a certified distance measurement. Projects that need measured separation or automatic braking require dedicated safety equipment in addition to video analytics.

Forklift and pedestrian deployment

Using camera rules to review mixed forklift and pedestrian areas

Forklift safety events are usually about location, direction, duration, and the relationship between people and vehicles. A camera can support review of a crossing, lane, loading area, or restricted zone when the scene shows the relevant paths clearly. It should not be presented as a replacement for traffic separation, vehicle safety systems, or site supervision.

Choose the crossing and lane views first

Prioritise loading bays, blind corners, aisle intersections, pedestrian crossings, door approaches, and battery-charging zones. The view should show the vehicle route and pedestrian side of the scene. A camera mounted too high or too far away may detect objects but fail to show the relationship needed for a useful event.

Set rules around movement and occupancy

Possible rules include a forklift entering a pedestrian-only area, travel against a defined direction, a vehicle occupying an access route, or a person remaining in a controlled loading zone. The project needs to define authorised exceptions and alert intervals so ordinary operations are not treated as incidents.

Give each event enough context

Store the camera, time, region, direction or dwell rule, full-scene image, and where available a video reference. This gives the safety team a basis for reviewing the traffic interaction instead of relying on a cropped detection box alone.

Test occlusion and busy operations

Racks, pallets, truck bodies, door frames, high-visibility clothing, floor reflections, and congestion can hide people or vehicles. Site testing should cover peak loading periods and confirm where camera coverage is suitable, where a second view is required, and when human review is necessary.

Related planning: Warehouse and logistics deployment guide. Camera rules work best as a documented layer alongside marked routes, training, access controls, and the site traffic plan.

Project inquiry

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