Warehouse safety
Warehouse safety starts with reducing collisions between forklifts and pedestrians – one of the most common causes of warehouse accidents. TCID combines STILL driver assistance systems, clear traffic routing and operator training to keep your warehouse safe without sacrificing productivity.
Why truck–pedestrian collisions are the biggest risk
Forklifts, electric pallet trucks and pedestrians share the same aisles, doorways and dispatch docks. Incidents usually come from everyday situations:
- Reversing with the rear view blocked, or someone stepping out from a rack end just as a truck turns in.
- Cornering too fast, especially with the load raised.
- Pedestrians not noticing an approaching truck in a noisy environment.
- A faulty truck going into the shift unchecked, or an operator who has not been properly instructed.
That is why three layers are needed at once: trucks that are easy to see and limit risk on their own, a clearly organised floor layout, and people who are trained and checked regularly.
Being seen and limiting speed automatically
Safety Light and warning zone lights
STILL Safety Light projects a blue cone of light onto the floor in front of the truck in the direction of travel. SafetyLight 4plus projects blue light spots about 5 m in front of and behind the truck, which is useful in areas with poor visibility or many bends.
Warning Zone Light projects two light strips onto the floor on either side of the truck; Warning Zone Light Plus adds a semicircle around the rear, the area where collisions typically happen when the truck pulls away or turns. Reversing lights, an acoustic reversing signal and a panoramic mirror can be added as well.
Speed limits by zone and in curves
STILL trucks can limit their own speed instead of relying on signs alone:
- Zone recognition: a wireless system automatically reduces speed when the truck enters predefined zones such as doorways, intersections and busy pedestrian areas.
- Curve Speed Control: adjusts speed to the steering angle when cornering, reducing the risk of losing the load; standard on some models.
- Speed reduction with raised forks: once the forks reach about 500 mm (or another set threshold), travel speed is reduced automatically.
- Narrow aisle warehouses: the Predictive Braking System on VNA trucks detects obstacles early to warn, slow down or stop the truck.
Cameras and Safety Assist: detect people, warn, intervene
STILL’s Safety Assist functions support the driver with multi-stage warnings and automatic intervention.
Rear area monitoring
Reversing Assistant Plus uses a 3D camera to show the area behind the truck in real time, distinguishes between people and objects, warns and can intervene in driving. The AI camera system detects people behind the truck, automatically reduces speed and stops the truck, with customisable detection zones. STILL Sentry uses radar and suits operations with frequent reversing.
Wireless collision avoidance
Trucks, pedestrians and fixed modules on doors communicate with each other. When a truck approaches, both sides are warned (warning zone); if it gets too close (protection zone), the system can brake the truck – even without line of sight. STILL iGo automated trucks use 360° safety laser scanners; see the warehouse automation page.
Choosing solutions by risk
| Risk | STILL solution | Effect |
|---|---|---|
| People stepping out from blind corners | Safety Light, SafetyLight 4plus | Blue light on the floor signals an approaching truck |
| Side or rear collisions | Warning Zone Light / Plus | Marks the danger zone around the truck |
| Reversing with blocked view | Reversing Assistant Plus, AI camera, STILL Sentry | Detects people, warns, slows down or stops |
| Driving fast through busy areas | Zone recognition | Automatic speed reduction in defined zones |
| Load falling when cornering | Curve Speed Control | Speed matched to steering angle |
| Hidden intersections and doors | Wireless collision avoidance | Two-way warning, can brake |
| Faulty truck entering the shift | Pre-Shift Check on STILL Easy Control | Check must be confirmed before full functionality |
Standard and optional equipment varies by model. For example, the STILL RX 60 2,5 – 3,5 t can be specified with Safety Light 4Plus, Curve Speed Control, a reversing camera and an on-screen pre-shift check; the narrow aisle STILL MX-X offers the Predictive Braking System. TCID matches the options to your specific trucks.
Pedestrian routes, pre-shift checks and training
Separate people and trucks: mark dedicated walkways, reduce crossing points, place convex mirrors at rack ends and set one-way traffic in narrow aisles. Aisle width directly affects safety – see our article on warehouse aisle design.
Digital pre-shift check: with the Pre-Shift Check in the STILL Easy Control on-board computer, the operator must confirm the truck’s condition on the display before full functionality is available. The company chooses the questions and can set the truck to limit its performance automatically if an answer is negative. Items worth checking are listed in our pre-shift safety checklist. Access control on the fleet management platform ensures only authorised operators can drive.
Training and inspection: operators need to understand why the truck slows down by itself and how to react to a warning. TCID instructs operators on using STILL trucks correctly and safely through our operator training service. Forklifts must be inspected under current regulations for equipment with strict occupational safety requirements, by a licensed inspection body; TCID helps prepare trucks, coordinates and rectifies faults – see safety inspection.
How TCID implements it
- Site survey: record blind spots, intersections, doors and dispatch docks.
- Proposal: select the right combination of warning lights, speed limits, cameras and collision avoidance for your fleet.
- Installation and configuration: warning zones, speed reduction thresholds, pre-shift check questions, access rights.
- Instruction: operators and team leaders learn to read warnings and follow traffic rules.
- Review: safety systems are checked during servicing and adjusted when the layout changes.
TCID has offices in Hanoi and Ho Chi Minh City and the Long Binh Service Center in Bien Hoa, Dong Nai.
Frequently asked questions
Can warning lights or cameras be added to STILL trucks we already use?
It depends on the model and year. Some systems, such as the Predictive Braking System, are designed to be integrated into existing trucks as well; other equipment needs to be checked against the actual configuration.
Do speed limits reduce productivity?
Curve Speed Control only slows the truck when needed; it still runs at full speed on straight sections.
With assistance systems in place, are pre-shift checks and training still needed?
Yes. Equipment does not replace a skilled operator.
Is TCID a forklift inspection body?
No. Inspections are carried out by a licensed body; TCID helps prepare trucks and rectify faults. Read more in our article on operator training and safety inspection.
Need to assess collision risks and choose the right safety solutions for your STILL fleet? Contact TCID for a site survey and quote.