A serious near-miss accident involving a high-speed forklift exposed a dangerous blind corner. Heavy foot traffic, expanding mezzanine use, and operator stress created a scenario where a single misstep could lead to catastrophic outcomes from injuries to shutdowns.
To immediately reduce the risk, the Facilities Maintenance team installed seven convex safety mirrors between November 10 and November 15.
Challenge
- Heavy foot traffic in mezzanine entrances, loft transitions, and climate-control areas
- Limited visibility for PIT operators approaching key intersections
- Operator stress causing slower maneuvering and production bottlenecks
- High potential for catastrophic outcomes including severe injury or fatality, equipment or infrastructure damage, and OSHA investigations and shutdowns.
Actions Taken
- Installed seven convex mirrors ($75–$100 each) in all high-risk intersections.
- Worked directly with PIT operators to determine optimal viewing angles for maximum visibility.
- Performed installation over five days while balancing daily maintenance calls
- Temporarily secured high-risk area with caution tape to keep areas controlled and safe.
Outcome
- Immediate visibility improvement, reducing collision risk across all blind corners.
- Operators and pedestrians reported higher confidence, resulting in smoother, faster, and safer traffic flow that directly improved overall productivity.
- Protected production continuity by preventing incidents that could halt operations.
- Mitigated potential PIT-incident costs ranging from $60,000–$500,000+ in medical care, litigation, lost productivity, OSHA penalties, and shutdown delays.
Precision in Action. Assurance in Every Step.
By proactively eliminating blind-corner hazards, the DFW1 team delivered a high-impact safety improvement at minimal cost. The convex mirror installation not only protected employees but also strengthened workflow efficiency, safeguarded uptime, and prevented severe financial and operational consequences.
Facilities Maintenance Supervisor Brandon Simpson put it best: “It is worth it. The little bit of labor, little bit of cost, is going to save somebody’s life.”
ABDM is ready to deliver the same proactive, high-impact safety results for what matters most: your people and your facilities.
