Checklist: How to Choose the Right Collision Avoidance System for Your Warehouse

1. Coverage & Detection Capabilities
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- Pedestrian Coverage (Tagged vs Tagless): Does the system detect only people wearing a device (tags) or also untagged pedestrians? For maximum safety, a system that combines both (tags for employees + AI camera or other sensors for visitors/unknown persons) offers comprehensive coverage. If you opt for a tag-only system, ensure you have a plan to manage visitors/contractors, etc.
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- Forklift-to-Forklift Collision Avoidance: Can the system also warn/prevent vehicle-to-vehicle collisions? In busy forklift traffic, preventing truck-on-truck impacts is important. Some UWB systems allow forklifts to detect each other’s tags too, creating a 360° vehicle awareness net. If you have lots of forklift traffic, this is a valuable feature.
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- Zone Coverage (Indoor/Outdoor): Verify the system works in all areas you operate. If you have yards or outdoor loading, ensure the sensors can handle weather and bright light (UWB and LiDAR, for example, work outdoors; some purely optical systems might not). Check range: a larger yard might need longer detection range or more infrastructure than a small indoor space.
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- Blind Spot Detection: Ask how the system addresses blind corners or obstructions. Solutions that rely on line-of-sight (cameras) may need supplementary sensors (mirrors or additional units in blind spots). UWB or RFID create a bubble through walls to some extent. Ensure whichever system can effectively “see” around your warehouse corners where accidents often happen.
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- Multiple Object Handling: Can it track multiple people/objects simultaneously? In a real scenario, there might be 3 pedestrians and anotherforklift all near one vehicle. The system should handle this without confusion(e.g., not fail just because two tags are present at once).

2. Accuracy & Reliability
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- Detection Accuracy: What is the accuracy of distance measurement or detection? Look for quantitative specs. UWB systems, for instance, might cite ±10 cm accuracy, whereas older systems might just say “detects within X meters” with no granularity. Higher accuracy means fewer false alarms and more trust in the system.
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- False Alarm Rate: Inquire about how the system minimizes false positives. Frequent nuisance alarms can lead operators to ignore or disable the system. Technologies like AI with object recognition or UWB with precise zones tend to have fewer false alerts. Ask vendors for any data or case studies on false alarm frequency and how their system filters out non-threats (e.g., filtering stationary objects, clothing reflections, etc.).
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- Environmental Robustness: Will it work in your specific environment conditions? For example, if your warehouse is dusty or has steam, a purely vision system might struggle. If you have a lot of metal racks (who doesn’t), an older RFID system might have patchy spots. So choose a system proven in similar environments: UWB is noted for low interference in metal-heavy areas, LiDAR and radar are great in darkness, etc. Ensure any IP ratings if water or outdoor exposure is expected (IP65+ for outdoor devices usually).
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- Maintenance & Calibration: Consider reliability over time. Does the system require frequent calibration (some camera systems might need periodic retraining or lens adjustment)? Are the sensors self-checking?Lower-maintenance systems (e.g., UWB tags with long battery life and no moving parts) will be more reliable day-to-day. Also ask about diagnostics – can the system alert if a sensor fails or a tag’s battery is low?
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3. Alerting Method and Effectiveness
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- Alert Types (Audible/Visual/Haptic): What alerts does it provide to operators and pedestrians? Ideally, it should alert both the driver and the pedestrian. Common alerts: forklift in-cab buzzer or light, vibrating wearable for pedestrian, warning lights in the facility. Check that the alerts are suitable for your noise level (i.e., loud alarm in a noisy mill might be ignored – maybe vibrating belt packs are better). Some systems also integrate with forklift controls to slow the vehicle – decide if you want passive alerts or active intervention.
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- Customization of Alerts: Can you adjust alarm volume, tone, or sensitivity easily? One-size-fits-all may not work; it’s good if you can tune it (e.g., louder alarm in high-noise zones, or different alerts for warning vs imminent collision). Also, consider language or symbols if you have a multilingual workforce – make sure visual indicators are intuitive (like a clear icon or color code).
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- Operator Interface: For any in-cab device or display, is it user-friendly and not distracting? A simple LED indicator or a small dash display might be used. Ensure it doesn’t obstruct view and is easy to interpret at a glance (“Green = clear, Red = person in path” etc.). If the system gives situational info (like direction of the pedestrian), check that it’s presented clearly.
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- Pedestrian Notification: If using wearables, are they comfortable and will workers actually wear them all day? Vest tags, helmet tags, or dedicated units – think about what’s most practical. Also consider if visitors or contractors come in – will you have spare units or some alerting mechanism for them? A good system should have a plan for that (maybe a pool of visitor tags or fixed beacons that cover untagged people in certain zones).
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4. Integration & Compatibility
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- Forklift Integration: Can the system integrate with all your forklift models and power sources? Some systems are simply add-ons (just stick a sensor with its own battery), while others tie into the forklift’s electrical system or CAN bus for interventions like automatic slowing. Ensure compatibility with electric vs diesel lifts, any ATEX requirements if in hazardous areas, etc. If you plan to use automated braking or speed control, check that the vendor offers interfaces for your brands of trucks.
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- Existing Systems: Do you already have some components (e.g., a fleet management system, or an older proximity system)? Look for something that can complement or integrate. For instance, if you have telematics that logs impacts, can the new system feed data into it or at least coexist without conflict? Some modern systems provide API or data export that could be tied into your central monitoring.
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- Scalability and Expandability: If you start with one warehouse and then roll out to others, or if your fleet grows, will the system scale easily? Ask about the maximum number of vehicles/tags it supports simultaneously. Also, check if the infrastructure (anchors, if any, or calibration) is easy to expand. A cloud-based or easily networkable solution may simplify managing multiple sites – for example, some vendors have cloud dashboards consolidating all devices. If you foresee adding AGVs or robots in the future, consider a system they could also use (UWB could guide robots too, whereas a pure camera on a forklift doesn’t help a separate robot).
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- Data & Analytics: Modern collision avoidance systems can output valuable data – near misses, frequency of alerts by zone, etc. If you care about continuous improvement, choose a system that logs events and provides analytics dashboards or reports. Ensure you can access the data (either through a portal or exports). This can help justify ROI later and identify problem areas. Compatibility with Power BI or other tools might be a plus if you’re data-driven.

5. Vendor Support & Track Record
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- Proven Performance: Look for case studies or references in your industry. A vendor that can demonstrate real reductions in accidents or successful deployments in similar warehouses will give peace of mind. Don’t be shy about asking for references to call. You want evidence that the system actually works in practice as advertised.
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- Installation & Training Support: Does the provider assist with installation and comprehensive training? Good vendors will offer on-site (or remote) training for your staff, ensuring proper use. They should help tailor the system during install (like setting zones appropriate to your site). Check if installation is done by them or DIY; ifDIY, what’s the complexity? Favor systems with a clear integration plan and support, so you’re not left figuring it out alone.
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- Maintenance and After-Sales: What is the warranty and service plan?Are software updates included (especially for systems with AI that might improve)? How easy is it to get replacement parts or additional units? Consider the longevity of the technology – UWB and major players likely will be around; some niche or proprietary tech might fade. Choose a vendor with stability and ongoing development.
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- Cost vs. Value: While not purely “support,” it’s important: consider total cost of ownership. Initial purchase plus any subscription (some systems have monthly software fees, e.g., for cloud). Also battery replacements or calibration costs. Then weigh this against the benefits (reduced accidents –which you can monetize, see Blog 4 ROI discussion). The cheapest system might not deliver the needed reliability or might become costlier if it’s not effective (one accident can wipe out years of “savings” from a cheaper choice).So ensure the features and support justify the price. That being said, ask about ROI cases – a serious vendor can often share how quickly their system paid back for other clients. Use those to guide your own cost-benefit analysis.
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6. Operational Workflow Integration
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- Workflow Disruption: Evaluate how the system will fit into daily operations. For instance, if using pedestrian tags, what’s the process to ensure everyone has them at shift start? If implementing speed control zones, will it slow down tasks significantly or is it negligible? Ideally, the system should enhance safety with minimal impact on productivity. Some systems have smart muting (like not alerting if forklift is stationary, etc.) to avoid unnecessary alarms. Ensure such features align with your work patterns so that it doesn’t frustrate operators.
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- Ease of Use: Simplicity is key. If something is too complicated, staff may not use it correctly. Look for an intuitive system: e.g., plug-and-play units, simple tag charging (or long battery life so charging is rare), maybeLED status indicators (so workers know their tag is functioning), etc. During demos, note the user interface – both for end-users and for managers configuring it. A good system will be user-centric, not just tech-centric.
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- Checklist of Safety Needs: Finally, cross-check the system against the specific accident causes you worry about (see Blog 6’s causes). Does it address those? For example, if you had an incident with a forklift backing into someone in a trailer, does the solution help there (maybe not – that’s a unique case requiring a trailer lock or camera). So ensure the system addresses your top concerns, and if not, what other measures fill the gap. The best choice might be a combination (e.g., proximity system + camera). Your selection process might thus consider how well a candidate system plays with others or if a vendor offers a hybrid solution already.

By walking through this checklist, you create a structured requirement set. You might even score each category for different solutions you evaluate. Here’s a quick summary list format(for actual use):

·     Detection: Covers pedestrians (tags vs. tagless?), forklift-forklift, indoor/outdoor range, blind spots, multi-target.

·     Accuracy/Reliability: Distance precision, false alarm minimization, works in environment(lighting, dust, etc.), maintenance needs.

·     Alerts:Types (audio, visual, haptic), who’s alerted (driver/pedestrian),configurability, user interface friendliness.

·     Integration: With forklifts (all models?), with current systems, scalability, data/analytics availability.

·     Vendor:Track record, support/training, warranty, roadmap (future updates), cost vs.benefit.

·     Operational Fit: Ease of use, minimal workflow interference, staff acceptance.

Tick off which criteria each prospective system meets. Aim for the one that checks the most boxes that matter to you.For instance, if reliability and precision are top priority, maybe UWB-based gets a big tick there. If budget is tight, maybe a simpler camera system gets a tick for cost but consider trade-offs in false alarms.

Remember, the “right” system is the one that will actually be used correctly and prevents accidents in your context. This checklist is a tool to ensure you cover all angles and make an informed choice grounded in your specific warehouse conditions and safety objectives. With the right system in place, you’ll be confident that you’ve significantly mitigated collision risks and moved your warehouse a big step forward in safety.