Introduction
In busy manufacturing environments, maintaining clear and safe pathways for both people and vehicles is critical. A leading engine manufacturer in the UK partnered with us to upgrade site safety and operational efficiency through a series of tailored visual safety interventions. The focus was to address known blind spots, reduce forklift-related risks, and optimise lorry and pedestrian movement across the site.
Company Background
This global engine manufacturer is renowned for its robust production capabilities and continuous improvement ethos. The UK-based facility plays a strategic role in engine assembly and component logistics, operating around the clock to meet customer demand. To support its growing workforce and busy inbound logistics operations, the company required an innovative approach to managing pedestrian safety and site traffic flow.
Challenge
Prior to the installation of our visual safety systems, the manufacturer faced a series of challenges related to high-traffic areas and poorly regulated pedestrian zones:
- Frequent Obstructions: Roller shutter access points were regularly blocked by unattended pallets and trolleys, disrupting workflow and posing safety risks.
- Inefficient Lorry Unloading: Lorries arriving on-site lacked a clear parking and unloading guidance system, causing congestion and misalignment with bay allocations.
- Blind Spot Hazards: Forklift trucks operating around internal corners often surprised pedestrians, leading to several near misses.
- Low Clearance Risks: Forklift operators occasionally struck low doorway structures, causing equipment damage and safety concerns.
- Limited Visual Reminders: Pedestrian PPE signage was outdated or non-existent in critical areas.
These challenges posed serious risks to both efficiency and workforce wellbeing.
Solution: Automated Visual Safety
To tackle these issues head-on, the manufacturer implemented a cohesive visual safety and traffic control package. Key components included:
- Hatched Safety Zones at Roller Shutters: High-visibility floor markings to keep loading/unloading zones clear of obstructions, helping to maintain smooth logistical operations.
- Lorry Bay Guidance System: A simple but effective layout with signage and bay indicators to direct drivers to the correct unloading zones, improving turnaround time and reducing confusion.
- Blind Corner Forklift Alert System: Motion-activated pedestrian warning signs to notify staff of active FLT operations in blind spots and high-risk internal junctions.
- Clatter Bars: Installed at vulnerable low-level doorways to pre-warn forklift operators of reduced clearance and avoid structural damage.
- PPE Warning Signage: Refreshed and repositioned signage to reinforce the use of high-visibility clothing, hearing protection, and safety footwear in pedestrian zones.
Implementation
The solution was delivered in a phased rollout to ensure minimal disruption to site operations:
- Site Survey: Walkthrough assessments to identify priority areas and user pain points.
- Custom Design & Planning: Tailored marking plans, signage placements, and activation zones for sensors and clatter bars.
- On-Site Installation: Carried out by trained personnel over several evenings and weekends to avoid peak activity hours.
- System Testing: Full check of sensor functionality, visibility in various lighting conditions, and impact resistance of clatter bars.
- Team Briefings: Short toolbox talks and visual guides introduced to staff to familiarise them with the new systems and expectations.
Results
Following the installation, the engine manufacturer recorded multiple improvements across safety and efficiency:
Operational Gains:
- Faster and more accurate lorry docking, with reduced driver confusion and site disruption.
- Roller shutter areas remained consistently clear, streamlining load handling.
Safety Outcomes:
- Marked decrease in near misses involving forklifts in blind corners.
- No incidents of low-level doorway impacts since clatter bar installation.
- Improved compliance with PPE requirements due to increased signage visibility.
Cultural Impact:
- Improved hazard awareness across the workforce.
- Staff feedback highlighted greater confidence in navigating shared spaces.
ROI:
- Seen as quick as 4 months in some areas and 12 months in others
Conclusion
By implementing a targeted suite of visual safety systems, the engine manufacturer successfully tackled long-standing site challenges and elevated both safety and operational performance. From structured lorry movements to smarter pedestrian alerts, the improvements demonstrate how visual clarity and physical cues can drive meaningful change in complex industrial settings.
This project highlights the manufacturer’s commitment to proactive safety culture and operational excellence, serving as a blueprint for other sites seeking similar upgrades.
