The outbound area is one of the warehouse’s busiest zones. Finished packages move by conveyor, where employees scan and sort them into large Gaylords for shipping. At the same time, forklifts operate nearby to remove full containers and stage them for transport. This constant overlap of people, conveyors, and heavy machinery creates a high-risk environment.
Before safety barriers were in place, employees at conveyor stations were directly exposed to forklift traffic. In one near-miss, a forklift with 12-foot forks passed under a pallet within feet of workers — an incident that could have caused severe leg injuries. Later, in July 2025, a forklift struck the conveyor system itself, underscoring the need to expand protection to both people and equipment.
Challenge
- Employees at conveyor stations exposed to forklift traffic risks.
- Forklift incident created near-miss with potential for serious injury.
- Conveyor equipment also vulnerable to collision damage.
Actions Taken
- Installed safety rails in outbound area to protect employees.
- Coached forklift operators on proper safety practices and behavior.
- Transitioned process from forklifts to manual pallet jacks, eliminating high-risk interactions.
- Expanded safety rail installation after a forklift struck conveyor equipment.
Outcome
- Employees shielded from forklift traffic.
- Conveyor system protected from further damage.
- Safer workflow established without reducing productivity.
Precision in Action. Assurance in Every Step.
This initiative demonstrates how targeted safeguards reduce risk without slowing operations. By combining physical barriers, process changes, and operator coaching, the team eliminated a major safety concern and strengthened overall facility protection.
