Because beyond the company, production, and equipment, there are human beings, we cannot stress enough how important it is to prioritize the health and safety of your workforce. Do the operations at your plant involve any risks? Perhaps you’ve already experienced an unfortunate incident? Was a serious accident narrowly avoided? Would a collision-avoidance system help protect your workers? That’s what we’ll try to determine in this article.
In Quebec, an average of 700 forklift accidents resulting in injuries are reported each year across all sectors, including four worker fatalities. That’s obviously way too much, but how can we prevent it?
Are you a project manager, occupational health and safety manager, maintenance manager, supervisor, production manager, or owner of a manufacturing company? This article is for you.
Are you looking for solutions to make intersections safer where forklifts operate? Do you want to maintain productivity in your factory while protecting the people who work there? This article aims to present the various options available to you based on your specific situation.
My name is Julien Cyr, president of Cyr Système and partner at Y&Co. I’ve always been passionate about technology; I’m a trained electromechanical engineer with over twenty years of experience in automation, control systems, custom industrial software design, and control panel manufacturing. Throughout my career, I’ve often been called upon to work in factories to help reduce risks. Here, I’d like to share the experience I’ve gained with you.
First, define the problem
The first step is to identify the problematic intersection, as well as its layout and the nature of the problem. Is it possible to improve the situation by controlling traffic in two directions, or is it necessary to address all four corners of the intersection?
If traffic flows primarily in the same direction (for example, north-south), it may be advisable to refrain from making changes to those corners of the intersection in order to maintain the efficiency of traffic moving in those directions. Instead, changes will be made to the other two corners to improve safety.
If the carts are expected to move in all directions (both north-south and east-west), measures will need to be taken at all four corners of the intersection. The challenge is to identify the solution that meets safety criteria while ensuring maximum traffic flow.
High-performance detection
The best way to reduce risks at an intersection is to install sensors that detect the movement of people and forklifts near intersections, as well as the direction in which they are moving. This detection system identifies and alerts operators to potential collision risks as they approach intersections.
When a forklift and a pedestrian are both near an intersection at the same time, a warning light comes on and begins to flash, alerting them to the risk of a collision. This flashing light is typically positioned below a mirror that allows the operator to see traffic coming from the other side of the intersection and, as a result, better anticipate its movements. Both the pedestrian and the forklift operator will be alerted to the other’s presence, thereby reducing risks.
To ensure optimal results—because there can be no compromise when it comes to employee safety—you should choose sensors whose technology is approved by the Canadian Standards Association (CSA), whether for pedestrian sensors or forklift sensors.
Solutions for specific situations
However, it’s important to be careful—intersections aren’t the only places where collisions can occur. Loading docks, for example, can also be accident-prone areas.
For strategic reasons, some companies may also choose not to issue alerts when pedestrians are present near a critical area. In such cases, the sensors must be configured to respond only when vehicles are passing by, in order to alert the occupants of the room to their presence.
Most companies choose to use warning lights to alert people in the detection zone to a potential collision. However, it is also possible to opt for audible warnings.
Who is the Bear Box Control factory-installed collision avoidance system designed for (and not designed for)?
The Bear Box detection system is specifically designed for any facility with constant traffic or as a preventive measure when there are multiple forklifts in operation. Since this is a situation involving significant risk, it is necessary to implement a safety system.
Warehouses with well-stocked shelves will also have a strong incentive to make their intersections safer. The poorer the visibility at the ends of the aisles, the higher the risk of collisions. Warehouses with narrow aisles are also more prone to accidents. Given the turning radius of forklifts, it becomes more difficult to avoid a collision.
The more forklifts are in operation at the same time within a company, the greater the risk. Factories that use multiple forklifts simultaneously will quickly see the safety benefits of installing a detection system.
Should you install it yourself or hire a professional to do it?
While businesses can install their own detection systems, we cannot stress enough how important it is to entrust this task to specialists to ensure that your equipment is properly calibrated and functioning correctly. As a general rule, professional installation of a security system takes about half a day per intersection, including staff training. The technicians then take the time to run several tests and ensure that everything is working properly to prevent any unfortunate incidents.
However, companies with only one vehicle in operation and low traffic volume may choose to opt for a less costly solution to secure their facilities, such as requiring the forklift to come to a complete stop when approaching an intersection. The focus would then be on raising awareness among forklift operators, as well as pedestrians working in high-risk areas of the plant. This measure inevitably results in a loss of production, but it may be the lesser of two evils compared to investing in a collision-avoidance system.
Pros and Cons of the Bear Box Control
Benefits:
- There are no chips to install on shopping carts or to give to pedestrians to ensure that the detection system works properly.
- It is powered by electricity, which eliminates the need to charge batteries and prevents potential malfunctions.
- The Bear Box Control requires very little maintenance.
- The sensors are certified, ensuring reliable detection and compliance with installation standards.
- L’installation est permanente, ce qui assure un fonctionnement en tout temps (aucun oublie possible par les utilisateurs (puces).
- The system is installed high enough to prevent it from being struck or damaged by a cart during routine operations.
Disadvantages:
- The Bear Box Control system requires a certain financial investment, the amount of which varies depending on the area to be covered, the number of intersections to be monitored, and the number of sensors to be installed.
- A physical installation is required at each intersection that needs to be monitored.
Comparison of the Bear Box Control with other options on the market
Several competing systems require the use of trackers, which can lead to serious consequences if they are forgotten.
These systems typically run on batteries, which also poses a risk if the device were to run out of power without the wearer noticing. The battery’s remaining charge can also have a significant impact on the detection system’s range, potentially warning of a possible collision at the very last minute.
There is also a significant risk associated with using these systems if a vehicle without a chip enters the area (such as a delivery driver or other external partner working on-site). The detection system will not activate in the event of an impending collision due to the absence of a chip.
Other competitors offering similar technology use sensors that are not approved, which can significantly impact the reliability of the safety system. These sensors rely solely on infrared technology, whereas Bear Box Control’s sensors use a combination of ultrasound and infrared technology. As a result, they may fail to function properly depending on the situation. When human lives are at stake, there should be no compromise in this regard.
There are also detection systems consisting of strips affixed to the corners of the various aisles as they approach an intersection. They are easy to install, but the sensors’ range is very limited, which results in a very short reaction time depending on the speed of the forklifts.
Most competitors are based in the United States. Here in Quebec, we find rudimentary systems in many factories, designed in-house by the companies themselves. These homemade devices are obviously less expensive, but they generally do not take into account the direction in which vehicles or pedestrians are moving, which often results in inaccurate information about the actual risk.
Designed with cost-saving in mind, these systems often have all the flaws of the Bear Box Control, without its benefits. Despite their good intentions, the creators of these DIY projects often lack the knowledge and experience needed to develop safety devices that are truly effective and safe.
Costs
The average cost of a Bear Box Control safety device is $3,000 per intersection. However, here are the various factors that affect the final price.
- The type of intersection (2-, 3-, or 4-way);
- The selected options (addition of mirrors, additional sensors, etc.);
- Other solutions tailored to specific situations.
Other points to consider regarding costs:
- There is an installation fee of approximately $500.
- The system comes with a one-year warranty covering parts and labor.
- You should budget for costs related to power supply if it is not already available near the intersections where the system will be installed.
What are the main concerns or questions regarding this product?
Yield
Many companies reach out to us after working with a competitor or after trying to develop an in-house system without much success. Their initial concerns usually revolve around the performance of our solution. “Will it work?”
If a client has multiple intersections that need to be secured, we often offer to set up a detection zone in a strategic location so they can see firsthand that our system works properly. We return to the site a few weeks later, once the trial has been successful. This approach allows us to prove our worth in the field.
Return on Investment
We often receive questions about the return on investment (ROI) of such an installation. Companies would like to see some kind of return. We need to help them understand that the return is harder to calculate from an accounting perspective, since it involves significant gains in health, safety, and improved working conditions for employees. In fact, the only potential performance gain is the efficiency of forklift movement. They can increase their speed at intersections when there are no identified risks.
The installation of a detection system is therefore primarily a matter of occupational health and safety. This is the main reason why people choose Bear Box Control.
Conclusion
The return on investment for a security system is difficult to quantify, since it is one of those measures put in place to prevent a tragic situation from occurring. It is rarely possible to say, “Today, the detection system saved a life,” yet it is essential, because once the irreparable happens, it is always too late and there is no turning back.
In an environment where human resources are essential to the smooth operation of businesses and difficult to replace, it is imperative to invest in a safety system that will effectively prevent collisions between forklifts and pedestrians moving through your facilities. An effective system must be equipped with industry-approved sensors and a fixed, stable power supply that leaves no room for human error.
You may not have experienced any forklift-related incidents at your company yet, but one thing is certain: don’t wait for one to happen. We recommend that you schedule an appointment right away so we can thoroughly assess your risks and implement the necessary measures to protect your workers.
If you have any questions about this article or would like more information about our conveyors, please don’t hesitate to contact us today by phone at 1-844-358-6035, by email at info@cyrsysteme.com, or by visiting us in person at our tool center located at 24 Beauchesne Street in Victoriaville.
You can also visit the Bear Box Control website and watch the product video.
Oh, and one last thing. Why Bear Box Control? The bear image chosen by Y&Co to represent its detection system symbolizes the robustness of its design, as well as its reliability, effectiveness, and ease of use.