Industry: Manufacturing
The Client
- Industry: Manufacturing
- Location: Sydney, NSW
- Type of Facility: Manufacturing Facility
A Sydney-based manufacturing facility operating a busy site with regular interaction between pedestrians, forklifts, and trucks required a coordinated set of traffic management upgrades to reduce the risk of vehicle and people interactions.
The Operational Challenge
The client conducted a series of risk assessments across the facility and identified multiple areas where the interaction between pedestrians and moving vehicles — including forklifts and trucks — presented an unacceptable safety risk.
Each area of the site presented its own operational characteristics, traffic flow patterns, and constraints. A single one-size-fits-all solution was not appropriate. The client required a partner capable of assessing each location individually and delivering a tailored safety solution suited to the specific risk profile of that area.
The systems also needed to be robust, reliable, and capable of operating effectively within an active industrial environment.
Objectives
The client required:
- Targeted safety solutions tailored to each area of the site
- Reduced risk of interactions between pedestrians and vehicles
- Reliable operation in an active industrial environment
- Manual and automated control options where appropriate
- Robust equipment suited to long-term outdoor and indoor use
- A single partner capable of delivering multiple solution types
Our Solution
We assessed each identified area of the site and designed a tailored safety solution to suit the specific risk and operational requirements of that location. Three distinct solutions were deployed across the site:
Radar-Activated Warning Beacons
In one area of the site, we installed a radar sensor configured to detect vehicle movement and automatically activate warning beacons when a vehicle was present. This provided real-time visual warning to pedestrians without relying on operator intervention.
Solar-Powered Manual Traffic Lights
In another area, we installed robust, solar-powered traffic lights that allowed the operator to manually control vehicle flow. This gave truck drivers the ability to safely shut off sections of the road while unloading their trucks, eliminating the risk of unexpected vehicle movement during loading operations.
Sensor-Triggered Industrial Projectors
In a further area of the site, we installed industrial projectors that project clear warning signage onto the ground when forklifts are detected in the area. This delivers an immediate, highly visible alert to pedestrians at floor level — exactly where the risk exists.
The Result
The client now has a coordinated, site-wide traffic management system with each area protected by a solution suited to its specific risk profile. Pedestrian and vehicle interactions are now actively managed through a combination of automated detection, operator-controlled traffic flow, and high-visibility ground projection.
The client was very happy with the system and the outcomes delivered, and has indicated they will be reaching out for further safety upgrades across the site in the future.
Key Client Benefits
- Tailored safety solutions matched to each area of the site
- Reduced risk of pedestrian and vehicle interactions
- Automated radar-activated warning beacons
- Operator-controlled solar-powered traffic lights for safe truck unloading
- High-visibility ground-projected warnings for forklift activity
- Robust, industrial-grade equipment suited to long-term operation
- Single-partner delivery across multiple solution types
- Trusted partner for ongoing site safety upgrades
