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Workplace Transport and Pedestrian Safety in Manufacturing
ZoneSafe improves health and safety in manufacturing industry by reducing collision-risk.
Health and Safety in Manufacturing Industry – The Dangers
Unintended transport hazards in the manufacturing industry, particularly where pedestrians and vehicles interact, significantly increase the risk of fatal and severe injuries from accidents. This danger is often exacerbated by limited visibility in environments where the movement of large loads and machinery can severely obstruct views and clear lines of sight.
According to RIDDOR data:
- The manufacturing sector experienced 16 fatal injuries to workers in 2023/24, with a five-year average of 17 deaths per year.
- Being struck by a moving vehicle caused 25 worker fatalities across all industries in 2023/24, representing 18% of all worker deaths.
The persistent and serious nature of transport-related risks highlights the critical need for robust safety measures in manufacturing. This is vital for protecting workers, and indeed, under health and safety law, employers have a legal duty to ensure, as far as reasonably practicable, their employees’ health, safety, and welfare.
Our pedestrian detection system actively boosts situational awareness and promotes safer practices within manufacturing facilities, effectively lowering the chance of collisions between vehicles and pedestrians.
We’re proud to protect workers and health and safety in manufacturing industry, delivering a tried-and-tested proximity warning system that promotes a ‘Zero-harm’ culture. Find out exactly what our customers say about ZoneSafe in our case study videos.
*These provisional figures will be finalised in July 2025. This allows HSE to account for any necessary adjustments or late reports that may come in.
Sector Statistics up to 2023/2024*
%
Non Fatal Injuries to Workers Struck by Moving Vehicles
x
Higher Fatality Rate Than Average Across Industries
Fatal Injuries to Workers Per Year
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Manoeuvring Blind Spots Safely With 360° Detection
Keeping your workforce safe on busy worksites operating heavy plant machinery is no easy task. Vehicle blind spots, concealed entrances, blind corners, obstructions and unexpected behaviours all increase the risk of a pedestrian being hit by a moving vehicle.
ZoneSafe proximity warning technology enhances health and safety in manufacturing industry. Unlike other solutions available on the market, such as an AI camera system, Zonesafe’s pedestrian detection system does not rely on line of sight, and it will detect pedestrian workers (even when they can’t be seen!) from behind walls, racking, and pallets, thanks to its clever use of RFID technology.
ZoneSafe Vehicle-to-Person Alert works by fitting an antenna to the vehicle. This creates a 360-degree detection zone around the vehicle, helping to eliminate vehicle blind spots. Pedestrian workers wear a ZoneSafe tag, which the antenna detects every time the pedestrian (and tag) enters the detection zone. Once detected, the in-cab control unit warns the driver via an audible and visual alarm, and the tag worn by the pedestrian vibrates, alerting the pedestrian to the danger of the approaching vehicle.
Activated Signage
Implementing ZoneSafe's vehicle-activated signage provides a practical solution to enhance onsite safety. Signs only flash when the vehicle is present, warning both site users and visitors located in the area to any approaching vehicles.
Pedestrian Access Control
Restricting site access to only your employees or anyone given a ZoneSafe tag reduces the risk of accidents. Only ZoneSafe tags open gates or barriers to a restricted area meaning they'll be detected and warned should they get too close to a moving vehicle.
Vehicle-to-Vehicle Detection
Reduce the risk of accidents between moving vehicles with ZoneSafe vehicle detection anti-collision system. Fitting any type of vehicle, the system provides two configurable warning zones, an outer pre-warning (or early warning) zone and inner (close proximity) warning zone.
Data Management
My.ZoneSafe, is our cloud-based insight and data management platform, which records and displays event data (such as near miss occurrences) to inform Health and Safety managers of potential hazards and collision hotspots.
Health and Safety in Manufacturing Industry Risks from Workplace Transport
It’s essential to segregate moving vehicles and pedestrian workers on your worksite. There are many different areas and situations on a manufacturing site where this isn’t always possible, such as any area where a vehicle reverses. Vehicle blind spots and site layout all increase the risk of accidents.
ZoneSafe works in any manufacturing environment, including:
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Food and Beverage Manufacturing
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Wood, Paper, and Printing Manufacturing
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Electrical Equipment Manufacturing
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Pharmaceutical Manufacturing
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Rubber and Plastic Products Manufacturing
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Textiles, Clothing, Leather, and Footwear Manufacturing
Improve Health and Safety in Manufacturing Industry.
Find out what other manufacturing sites say about ZoneSafe
Mondi is a leading manufacturer in packaging and paper, employing around 26,000 people across more than 30 countries.
“ZoneSafe’s proximity warning system has been a crucial addition to our warehouse safety strategy, especially in areas with blind corners. This system has significantly reduced collision risks and increased awareness amongst our team.”
Other Projects We’ve Delivered
Virginia Hayward,
Warehousing & Logistics
Warehousing & Logistics
Virginia Hayward has reported a dramatic reduction in the number of near misses and accidents since the implementation of ZoneSafe.
Gray Forklift Services,
Forklift Truck Supplier
Forklift Truck Supplier
Gray Forklift Services Ltd selected ZoneSafe to manage their fleet of trucks and health and safety needs.
SAAM Ports,
Cargo Support Services
Cargo Support Services
SAAM carried out an evaluation project to find a solution to protect personnel and assets from vehicle collisions within their ports.
Liberty Steel,
Steel Manufacturer
Steel Manufacturer
Liberty Steel implemented a safety and asset protection system designed to stop cranes from colliding.
See how ZoneSafe can provide a solution for you Get in touch