Warehousing and Distribution
Warehouse Traffic and Forklift Controls
A high-throughput distribution center tightened pedestrian interfaces, dock discipline, and operator accountability after recurring near misses.
Challenge
Growing order volume increased forklift–pedestrian interaction at cross-aisles and docks. Near misses were reported informally and corrective actions stalled between shifts.
Approach
- Traffic pattern and dock observation study
- Updated PIT expectations and coaching cadence for supervisors
- Practical operator refreshers tied to site-specific hazards
- Simple near-miss intake and corrective action tracking
Outcomes
- Defined pedestrian routes and intersection controls
- Supervisors given a weekly observation checklist
- Near-miss reporting became visible to leadership
- Corrective actions closed with owners and due dates
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