International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 12 Issue: 07 | Jul 2025
p-ISSN: 2395-0072
www.irjet.net
Beyond Line-of-Sight Vision Assistance for Forklift Operations Ashwini S Savanth1, P S Ravindranath2, Sukruth Raghavendra R3, Rashmitha R Shet4, Shamitha M5 1Associate Professor, Dept of ECE, BNMIT, Bangalore, Karnataka, INDIA. Orchid ID: 0000-0003-2421-8429 2Senior Vice President, Senquire Analytics Pvt. Ltd., Aundh, Pune, INDIA 3 Student, ECE, BNMIT, Bangalore, Karnataka, INDIA 4 Student, ECE, BNMIT, Bangalore, Karnataka, INDIA 5 Student, ECE, BNMIT, Bangalore, Karnataka, INDIA
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Abstract - The Warehouse-Material Handling Assistant is a
safety, minimize material mishandling, and address the difficulties associated with backward movement in forklifts without rear vision. Every year, about 95,000 people are injured and 100 workers are killed in forklift accidents, according to the Occupational Safety and Health Administration (OSHA) [1]. Nearly one of every six workplace deaths involves a forklift, so safety is paramount in warehouse operations. The unique design of forklifts also makes them more susceptible to potential accidents. Forklifts are heavier in the rear to balance loads in the front, which can make for an uneven weight distribution. Loads, carried in front, can block or limit the operator’s view. Besides the potential for injury or death, accidents can be costly. The National Safety Council reports that each injury requiring medical attention costs companies $42,000 and each workplace death averages more than $1.2 million in employer expenses. These numbers include lost wages, medical expenses, and administrative and employer costs [2]. On top of that, there may be property damage or damage to machines that require costly repairs. This combination of factors underscores the critical need to address safety and efficiency in warehouse operations. The safety of both workers and equipment operators is paramount, as accidents and mishandling incidents can result in injuries, damage to goods, and financial losses. By understanding these issues and seeking viable solutions, we can enhance workplace safety, optimize material flow, and ultimately improve the overall efficiency of warehouse operations. For warehouse owners and operators, the best solution to these challenges to prevent forklift accidents requires a twopronged approach: operator and worker training along with technology to mitigate safety concerns. Warehouses are hubs of activity with workers moving in different directions at the same time, especially during peak hours. Employees may be moving rapidly between areas as they pick, pack, and ship at the same time while other workers are manning forklifts to haul and unload pallets. Besides being busy places, there is often a lot of ambient noise in warehouses. Pedestrians may not see forklifts until it’s too late. They may also be caught unaware when turns or sudden stops occur. So, there’s a high potential for collisions between pedestrian and forklift accidents [6], [7], [8], [9].
strategic initiative designed to address the challenges of multitier stack warehouse environments through a combination of embedded hardware and software. The primary objective is to enhance safety and minimize mishandling risks during material handling operations, aligning with the vision of autonomous manufacturing and aiming for zero wastage, zero accidents, and zero defects. The methodology employs an integrated system comprising proximity sensors, cameras, and a touchpad Human-Machine Interface (HMI). This interconnectedness ensures a responsive system that aligns with the objectives. The software script processes individual frames to overlay lines representing lanes or paths, enhancing frame visuals for computational steps or visual interpretation within the system. In summary, the Warehouse-Material Handling Assistant project addresses the challenges in multitier stack warehouse environments through an integrated approach that leverages hardware and software. It aims to enhance safety, minimize mishandling risks, optimize efficiency, and promote sustainability. The development of the BLOS Dashboard View system, which uses cameras and proximity sensors, redefines standards in warehouse operations, ensuring a cohesive and responsive solution for modern material handling needs. Key Words: Forklift, Beyond line of sight, Vision assistance, Embedded device, proximity sensors, camera, GUI
1.INTRODUCTION In the dynamic and fast-paced world of warehouse operations, material handlers play a pivotal role in ensuring the efficient flow of goods. However, their tasks often involve operating equipment within multi-tier stack environments, where alignment, anchor-based positioning, and orientation challenges can pose significant safety and material handling risks. These concerns are further compounded by material handlers frequently operating their equipment beyond the line of sight. Furthermore, forklifts lacking rear vision face difficulties manoeuvring in reverse, hindering their ability to navigate backward effectively. This impediment in reverse movement poses an additional challenge, emphasizing the need for a comprehensive solution to enhance operator
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