Intelligent hazard zone monitoring system
Background
Our client runs a plant in Łódź that manufactures plastic tubes for the cosmetics industry. In the unloading dock area, a risk of collision between forklifts and pedestrians was identified – the transport route crossed a walkway, and tall loads badly restricted visibility. The health and safety department concluded that standard measures such as mirrors and permanently lit beacons were not enough.
Objective and solution
The goal of the project was a system that responds only when a hazard is real. TSafety designed a solution built around four cameras and an AI compute unit. The system analyzes the video feed in real time, detecting both pedestrians and forklifts in the dock zones.
The moment a hazard appears, the system triggers a warning: a projector puts the message “Caution forklift” on the floor, and a light and sound beacon alerts the operator. The alarm fires only when a pedestrian is genuinely in a dangerous spot.
Results and refinement
The first phase alone produced measurable results – the system reliably stopped situations where pedestrians stepped into the path of a forklift. Alarm response was immediate, and traffic began to flow more smoothly and more safely.
During testing, the TSafety team refined the algorithms, training them to recognize forklifts partly hidden behind their load. Working with the client’s health and safety department, we also introduced an organizational change – zones were marked where goods may not be set down, which cut the number of false alarms significantly.
Benefits
The TSafety installation made a real difference to safety in the dock area, tying advanced image analysis into the everyday running of the warehouse. The system raises an alarm only when the risk is real, which keeps it fully effective and supports the safety culture across the facility.
Why TSafety
TSafety delivered a system grounded in field experience and in technology matched to how a production plant actually runs. The scope covered risk analysis, system design, hardware selection, algorithm development, installation and support in service. The result meets health-and-safety requirements and also creates a business advantage — safety is built into the logic of the process instead of slowing it down.
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Every day you wait is another chance for an accident or a costly shutdown. TSafety helps you protect your people, your equipment and your margins – and the first step is easy.
Call or write today. We will set up a free consultation and show you how our systems can raise the safety standard across your facility.
Do not wait for an accident to happen – act now.