Impact Monitoring System for Forklift Safety

Impact Monitoring System for Forklift Safety
Published On:April 27, 2018 Revised On:July 1, 2023

Enhance visibility within the warehouse through the utilisation of a forklift impact monitor. Envision the capacity to avert the exasperation associated with encountering dented racking systems. These damages not only entail expensive repairs but also compromise the weight capacity of the racks.

What is a Forklift Impact Monitor?

A forklift impact monitor is a device that records, measures, and tracks any impact caused by a forklift truck on various objects, including equipment, walls, and racking systems. When an impact occurs, the monitor captures essential information such as the time of impact, individuals involved, and the severity of the impact. This critical data is automatically collected and stored in a centralised repository called a Dashboard.

In today’s manufacturing, distribution centre, and warehouse operations, the frequency of impacts tends to rise due to high employee turnover, often exceeding 40% annually. This necessitates significant investments in forklift training, leading to higher maintenance and facility repair costs.

By embracing a data-driven approach, valuable insights from the forklift impact monitor can be leveraged. Collecting valuable data that allows for a deeper understanding of operations becomes crucial as impacts occur. Operations managers can understand where impacts are occurring, the timing of impacts (including specific shifts if applicable), and whether any driving patterns are evident. With these insights, informed adjustments can be made to mitigate impacts.

Why Monitoring Forklift Impacts?

Forklift operators strive to meet productivity targets; accidents can occur as they navigate tight spaces, inadvertently colliding with racks or damaging dock doors during loading and unloading tasks. Unfortunately, these incidents can have a detrimental effect on productivity and overall results.

Implementing a forklift impact detection system mitigates risks and contributes to a safer and more efficient operation. This investment offers numerous benefits, such as measuring safety performance across the fleet, enhancing operator accountability, improving training for drivers who require additional guidance, and identifying the root causes of damages. By using the forklift monitoring system, warehouse managers can proactively take steps towards creating a safer workplace and improving the bottom line.

How Does Forklift Monitoring Work?

Impact monitoring technology enables specific parameters for notification and data collection based on the magnitude of impact to be set. For instance, the system can notify when impacts reach a certain G force, such as 3G (equivalent to the impact felt at 66 mph).

Upon a 3G impact, a notification is received via text, email, or both, while the associated data is captured, reported, and ready for analysis within the online Dashboard. The dashboard provides graphical representations of the impact data, allowing for the visualisation of results.

Access to the dashboard is available to decide on appropriate actions to minimise the number of impacts. Various aspects of the forklift can be monitored, ensuring a comprehensive view of its performance and potential areas for improvement.

Improve Warehouse Safety and Keeping Workers Safe

When using the forklift, the monitoring system incorporates an alert system that triggers notifications in case of unsafe actions or potential collisions. For example, if a forklift operator exceeds a safe speed limit, attempts an improper manoeuvre, or gets too close to another vehicle or pedestrian, the system can issue immediate alerts to both the operator and relevant supervisors.

These alerts act as timely reminders and warnings, allowing corrective action to be taken promptly, thus preventing accidents or injuries. Unauthorised or untrained individuals operating forklifts can pose significant risks to themselves and others in the warehouse. A forklift monitoring system can help prevent such situations by implementing access control mechanisms.

Before starting a forklift, operators must authenticate themselves using biometric identification, key cards, or personal identification numbers. This ensures that only authorised personnel can operate the equipment, reducing the chances of accidents caused by inexperienced or untrained individuals.

Increase Productivity and Performance of Forklift Drivers

A forklift monitoring system can enhance the productivity and performance of forklift drivers. This system offers several benefits by providing real-time monitoring and analysis of impacts.

Firstly, it increases driver accountability. Monitoring their impacts encourages drivers to follow safety rules and exercise greater caution and precision while operating forklifts. This heightened sense of responsibility translates into reduced accidents and damages, leading to improved overall productivity.

Secondly, the impact monitoring System serves as a valuable training tool. It provides objective data on each driver’s performance, highlighting areas where additional training or guidance may be necessary. By identifying specific patterns or behaviours leading to impacts, targeted training programs can be developed to address those areas and enhance the skills of forklift drivers.

In addition, the data collected by the impact monitoring system can be analysed to identify trends and patterns. This valuable information allows management to make informed decisions regarding workflow optimisation, equipment placement, and operational adjustments. By leveraging this data-driven approach, productivity can be further enhanced through continuous process improvement.

Enhancing Service Life and Reduce Maintenance Cost

Connectivity is pivotal in gathering, sharing, and analysing crucial forklift information, enabling enhanced service management and facilitating the shift from reactive to proactive maintenance approaches. Providing maintenance managers with the ability to stay ahead of forklift repairs and service is valuable.

With proper scheduling, pre-ordering of parts, and timely servicing, forklift and operator downtime can be minimised. This proactive approach allows for efficient operations and optimises the investment in forklift fleets. Moreover, operations managers can maximise the lifespan of forklifts by utilising readily available information, which serves as proof for necessary replacements when the time comes.

Furthermore, the forklift safety system enables proactive maintenance and repairs. By promptly detecting impacts, maintenance teams can quickly assess any potential damage to the forklifts and take appropriate action. This preventive approach minimises the risk of unexpected breakdowns or equipment failures, ensuring uninterrupted operations and maximising productivity.


In conclusion, a forklift impact monitor enhances visibility within the warehouse and provides valuable insights to improve operations. By capturing and analysing impact data, warehouse managers can make informed adjustments to mitigate damages and increase safety.

Implementing a forklift monitoring system increases driver accountability, gets training and facilitates tar enabling data-driven decision-making for workflow optimisation and continuous process improvement.

Additionally, the system supports proactive maintenance, reducing downtime and maximising the lifespan of forklifts while minimising unexpected breakdowns and repair costs. By using this technology, warehouses can enhance productivity, improve performance, and ensure a safer and more efficient operation.