Predictive Technology Is Improving Warehouse Safety
AI-driven predictive technology is reshaping warehouse safety. From smart cameras and sensors to wearables and VR training, new tools are helping managers detect risks early, prevent injuries, and create safer, more efficient workplaces.
It’s widely known that warehouses are one of the most injury-prone working environments. Warehouse workers are more than twice as likely to experience an injury compared to the national average. Warehouses are loud, fast-paced, with heavy machinery, vehicles and thousands of goods stacked high, which gives managers multiple types of injury concerns to mitigate.
However, new predictive technology is easing the burden on warehouse managers’ shoulders. Predictive technology can notify managers when it detects an anomaly that could cause an injury, minor or serious.
What is predictive technology?
Predictive technology combines AI, machine learning, data mining and predictive modelling to rapidly forecast future events and opportunities. Tech companies are installing it into products such as cameras and sensors, as it can help prevent injuries while also detecting signs of faulty machinery.
Assessing environments, equipment, sensors and worker activity gives warehouse managers important insights to adjust workflows before an incident forces a serious investigation. Ultimately, predictive technology helps warehouse managers run a safer, more productive warehouse.
Why predictive technology is in high demand
Safety is a constant priority for warehouse management. US warehouses logged an injury rate of 4.8 cases per FTE. Predictive technology is in demand as warehouse managers know that many injuries are preventable.
Predictive technology helps warehouse managers stay proactive to make warehouses as safe as possible. A safer warehouse is a more productive and profitable one. Not only are injuries and fatalities awful things to witness on your premises, but the aftermath could also involve downtime, injury claims and increased turnover. Workers don’t want to work in an unsafe environment. A culture of safety serves everyone.
How predictive tech is preventing injuries in warehouses
Predictive tech is not out to replace human judgment. Human risk analysis is still paramount, but combining it with predictive tech gives warehouse managers a better chance of keeping everyone safe.
Predictive tech helps warehouse managers with:
- Visibility: Managers put a great deal of trust in workers that they are working safely. Micro-management isn’t desirable in warehouses, so predictive tech can help keep workers safe.
- Early detection: Injury prevention is the goal. Alerts can notify management to make changes where injury concerns are found.
- Improved lifting form: Lots of common injuries are caused by dangerous movements. Predictive tech can catch them to ensure workers use proven techniques to avoid injuries.
- Helping cultivate a culture of safety: Seeing predictive tech in warehouses shows workers that employers take safety matters seriously.
Common predictive technologies found in modern warehouses
AI-powered security cameras
The fast-paced and complex nature of warehouses inevitably leads to a high number of injuries. A lot is happening under one roof. It’s not realistic for management to consistently detect every risk. Smart CCTV cameras are changing that. They evaluate and assess environments in real time and are effective at detecting anomalies, which could be hazardous.
- Unsafe areas: AI detects puddles, leaks, slippery floors, etc. that present hazards. This alone can help prevent slips, trips and falls, which make up the majority of injuries in the workplace – especially in warehouses.
- Large crowds: A crowd gathering could mean many things. It could be an argument taking place or workers assisting a seriously injured colleague. Whatever the reason, large crowds need to be addressed as they could lead to more danger.
- Forklift violations: Forklifts are responsible for around 25% of all incidents in warehouses. Cameras can improve safety as they detect forklifts speeding and when they steer into unauthorised zones.
- Poor lifting techniques: In the US, ergonomic injuries are most common in warehouses. Cameras can detect dangerous load handling techniques. Poor lifting form can be detected, so management can check in with them before they sustain an injury.
- Compliance issues: Personal Protective Equipment (PPE) should be provided and worn at the appropriate times. However, it’s commonly forgotten. Cameras can spot missing hard hats, harnesses, or goggles, so management can remind them to avoid preventable injuries.
- Restricted zones & equipment: Managing access controls for zones and machinery is a difficult danger to spot with the naked eye. Cameras can detect unauthorized personnel or if someone isn’t wearing the appropriate footwear or PPE.
- Personnel in unauthorized zones: Site visits can lead to unauthorized personnel standing in zones that pose a danger. Access controls, keycards and sensors can work together to alert management when unauthorized personnel are causing a disruption that could lead to an injury.
- Threatening behavior: Fights between workers can occur. Tension between workers can be hard to notice from afar, from smart cameras that feature Natural Language Processing (NLP) to detect threatening language, allowing the management team to intervene before an argument escalates any further.
Smart sensors
Sensors, too, have evolved rapidly thanks to AI technology. They can assess environments in real time to detect potential hazards that can fall under the radar.
Smart sensors can help detect:
- Gas leaks
- Smoke/fire
- Noise levels
- Vibrations (structural stress)
- Temperature
- Humidity
- Air quality
- Smoking and vaping.
Predictive machine maintenance
Malfunctioning equipment can be dangerous. Machine performance often slips in discreet ways that are barely noticeable before it breaks down. Predictive maintenance uses advanced analytics, smart sensors and machine learning to predict when equipment is likely to break. Servicing can be planned on a schedule to reduce machine downtime and the risk of injuries.
Wearable tech
Wearable tech has been used in warehouses for a while, a common example being helping workers pick orders more efficiently with wearable barcode scanners. Now there’s an increase in wearable devices used to help prevent injuries.
Sensors can be placed in clothing to monitor employees' posture. Poor form can be
corrected before it leads to injury. Workers’ fatigue levels can also be monitored as fatigue invites human error, which can lead to injuries.
Predictive tech used in warehouses:
- Posture sensors: Musculoskeletal disorders, back injuries and repetitive strain injuries are common types of injuries in warehouses. They are largely caused by poor lifting/carrying form, posture and repetitive movements. Companies are making a number of exoskeleton suits built for specific tasks. Activity is tracked and then gives feedback in real-time to correct form.
- Proximity sensors: Collisions are a constant concern in warehouses. Workers on the floor can wear belts fitted with haptic sensors that alert them when a forklift/vehicle is in close proximity. Belts can also be configured to alarm workers when they are approaching dangerous areas, such as loading bays or when a crane is operating. These were also used to ensure “social distancing” was being followed during the height of the COVID-19 pandemic.
- Environmental monitors: Smart sensors can detect numerous health hazards such as toxic fumes, extreme temperatures, or concerning humidity.
- SOS buttons: Working in isolated zones can be very dangerous. Wearable tech features an SOS button to instantly alert teams if a worker has been injured and needs urgent assistance.
- “Hands-free” equipment: Fatigue increases the likelihood of injuries and repetitive strains. So, any improvements to boost efficiency are encouraged. There’s been a rise in smart glasses and wearable barcode scanners becoming more prevalent to help floor workers focus.
VR training
Robust training is hugely important, but this is a struggle as every warehouse is different and it’s tough to give new starters the training they need. It’s a big concern as employees are far more likely to sustain an injury during their first few weeks of work. VR training can help new starters adjust to a warehouse environment, so they’re better prepared before their first shift.
VR tools can create a digital replica of your warehouse. Simulations can be created to demonstrate common dangers to look out for, such as working alongside forklifts, working from heights and correct Lockout/Tagout (LOTO) procedures. VR training solidifies the importance of safety as the lessons are far more immersive than traditional, yet less engaging training manuals.
Integrated systems
It’s not safe, nor is it efficient for warehouse managers to be alerted multiple times a day to possible dangers. Warehouses are safer when security and predictive tech systems talk to each other, so they can complete emergency actions when required.
For example, if a sensor detects a dangerous chemical in the air, a sensor could trigger an evacuation alarm if systems were integrated. Countless employees would be put in harm’s way if the manager wasn’t available to review the alarm for a few minutes. Integrating systems helps managers keep everyone safe. Protocols can be configured to take the right steps to prevent as many injuries as possible.
Predictive tech is improving warehouse safety
New advances in predictive tech are helping warehouse managers detect injury threats that are difficult to spot in a fast-paced warehouse. A combination of AI cameras, sensors and other smart tools can trigger alerts that help reduce the high number of injuries and fatalities that warehouses see every year.