Adopting AI Solutions to Improve Forklift Safety
Forklifts are essential to modern industrial operations—but they also rank among the most dangerous pieces of equipment on any site. With pedestrian collisions still a leading cause of workplace injuries and fatalities, traditional safety measures are no longer enough.
This guide explores how AI-powered detection systems, like Blaxtair®, are transforming forklift safety by delivering real-time pedestrian recognition, minimizing false alarms, and adapting intelligently to your unique work environment. Whether you’re in logistics, construction, mining, or public works, this practical guide will help you evaluate, implement, and scale the right AI solution for your operations—just in time for National Forklift Safety Day.
Why AI Solutions Matter in Forklift Safety
Every year, forklift-related accidents lead to serious injuries and fatalities across industrial sectors. As operational speed and complexity increase, traditional safety protocols are no longer enough.
With AI-driven pedestrian detection systems, companies now have access to proactive tools that:
- Detect pedestrians in real time
- Eliminate false alarms that cause alarm fatigue
- Warn operators only when there is real danger
Adopting these technologies—especially in preparation for National Forklift Safety Day (June 10)—can help create safer, smarter work environments.
Key Criteria for Selecting an AI Forklift Safety System
The success of any AI safety system depends on four core criteria:
High Accuracy
Effective solutions can distinguish pedestrians from objects in real time, even in complex environments. This is crucial to avoid unnecessary slowdowns and ensure trust in the technology.
How to evaluate the detection performance of an AI system?
Here are some practical examples of ‘’stress tests’’ to perform:
Ability to detect pedestrian in very low light conditions
Ability to detect a pedestrian from behind, crouching on the ground
Ability to detect partially hidden pedestrians, even when only one arm or leg is visible
If the camera is installed on the mast, ability to maintain the detection zone (= danger zone) whatever the inclination degree of the mast.
Do not hesitate to ask for these simple tests. Blaxtair is designed to pass all these tests with unmatched performance.
Low Latency
The system must alert the operator immediately, without delay, to give them enough time to avoid a collision. Every millisecond matters.
ISO standards and safety authorities recommend a latency time of less than 300ms and ideally 200ms for pedestrian detection solutions. Beyond 300ms of latency provides insufficient time to prevent accidents.
Blaxtair has multiple certifications attesting to its performance and offering the guarantee of a reliable product and successfully meets the ISO16001 standard with a latency of 200 ms.
Low False Alarm Rate
Frequent false alarms lead to operator fatigue and ultimately disengagement. They erode operator confidence and attentiveness. The ideal system minimizes these events to preserve efficiency and trust.
Evaluation tip: Ask providers to quantify false alarm rates. If a system triggers more than one false alarm per shift, it may reduce driver awareness and system efficiency, rather than improve safety.
Blaxtair generates only relevant alerts for the driver, avoiding nuisance alarms and alarm fatigue. Thanks to its unique database and the use of deep learning models trained on thousands of real-world scenarios, Blaxtair Pedestrian Detection achieves unparalleled specificity, with a false alarm rate of less than a single occurrence per day.
Reliable Updates & Support
Ensure your provider offers:
- Continuous AI software updates
- Remote diagnostics
- A responsive technical support and localized service teams, so your system evolves with your operations and risks.
Defining Your Needs with a Provider: Every Site Is Unique
No two operations are the same. The safety system must align with your facility’s unique risks, traffic flows, and layout.
Collaborative Risk Assessment
You provider should be able to make a smooth and rapid audit to define the best way to proceed. Work directly with your solution provider to:
- Map high-risk zones (pedestrian crossings, shared aisles, blind spots)
- Define the use case: type of vehicles, kind of operations, risks associated
- Rapidly analyze operational workflows
- Identify areas requiring zone-based detection or custom alert thresholds
A consistent risk assessment ensures maximum protection with minimal disruption.
Customization Based on Environment
AI safety systems like Blaxtair must be fine-tuned to the specific challenges of your industry and site type. Examples include:
- Warehousing & Logistics: Fast-paced environments where forklifts interact with foot traffic daily. Detection zones must be calibrated to tight spaces and shared aisles.
- Construction & Public Works: Outdoor operations with changing terrain and visibility. Blaxtair’s High Dynamic Range sensors ensure robust detection by adapting to dusty or dynamic environments.
- Mining & Quarries: High-risk, rugged zones where visibility is poor and vehicle-pedestrian separation is often weak. The system’s ability to function in harsh, uneven terrain with low lighting is critical.
- Municipal & Public Operations: Sites involving road maintenance or urban logistics need AI that can handle mixed pedestrian behaviors and unpredictable movement.
Customization ensures fewer false positives, better adoption by operators, and maximum safety impact.
How to Deploy: Start Small, Scale Smart
Initial Test Phase
A demo in an office is not enough to assess a solution. Begin with a pilot project on a select number of forklifts and operational areas. Evaluate the system’s responsiveness, accuracy, and integration with your existing workflows.
Optimize with Operator’s Feedback
- Use the pilot phase to gather operator input
- Adjust alert ranges, detection angles, and alarm sensitivities
Full Deployment
Once validated, proceed with phased implementation across all relevant machinery and departments. This helps control cost, minimize downtime, and train staff progressively.
Installation & Maintenance: Fast, Simple, Scalable
- Installation: Typically requires only a few hours per technician per machine
- Compatibility: Blaxtair fits a wide range of industrial vehicles with minimal adjustments
- Maintenance: Designed for long-term use, with remote updates, minimal downtime, and rugged hardware tested in demanding conditions
Blaxtair in Action: Real-World Results
Over 25,000 Blaxtair systems have been deployed in more than 50 countries, across all “off road” environments:
- Logistics warehouses and hubs, with high traffic and co-activity
- Industrial zones and manufacturing sites in all sectors, and for all types of operations
- Mining and quarries, with highly challenging fields of operation
Global leaders like ArcelorMittal and Forvia have seen tangible drops in pedestrian-vehicle incidents.
With a robust network of partners and certified installers, localized support is available across the most important economic zones: e.g. North America, Europe and Asia.
Compliance and Safety Leadership
Deploying AI safety systems isn’t just about technology—it’s about meeting and exceeding compliance requirements.
Check if the solution meets regulatory standards and was assessed and acknowledged by safety or governmental leading institutions.
Blaxtair helps organizations meet and exceed international safety standards:
- Aligned with OSHA safety initiatives, offering data-driven insights and proactive risk alerts.
- Recognized in Europe: Winner of the EuroTest Prize by BG BAU, a leading German safety authority.
- Certified compliance: Meets key standards such as ISO 16001 and VDI 4482, reinforcing its reliability and technical rigor.
More than a compliance tool, Blaxtair enables companies to lead by example, making pedestrian safety a core value and a lever for operational excellence. Its real-time risk feedback loop ensures continuous improvement, rather than one-off prevention.
Step into the Future of Forklift Safety
This National Forklift Safety Day, take action to protect your teams with cutting-edge AI solutions.
- Choose an AI system with low latency, high accuracy, and a proven track record
- Tailor the deployment to your site with expert guidance
- Pilot, optimize, and expand confidently
Blaxtair makes it easy to move from planning to protection—because every life on site matters.
