Measurable Warehouse Safety: Automatic Detection of Forklift Zone Violations and PPE Compliance

Every warehouse has safety rules; few have evidence that those rules are followed. How many forklift-lane violations happened last week, for how long, and in which zone? In most warehouses the answer comes from a supervisor's memory — unmeasured, inconsistent across shifts, and impossible to audit.

Video-based safety monitoring turns painted floor lines into digital zones with rules. Monitoring areas are drawn directly over the camera view — docks, security zones, forklift lanes — and one camera can hold several zones with different rules, such as maximum dwell time. When the layout changes, zones are simply redrawn from the application in minutes; no camera relocation, no technician visit.

Beyond position, the system assesses personal protective equipment. Each event is summarised in plain language with the visual findings behind the classification — for example, a person wearing a dark short-sleeved shirt with no helmet, no safety vest, and no coverall. A weekly safety dashboard shows violations this week, the most-violated zone, a seven-day chart, and the latest incidents, each linked to clip evidence — objective material for team briefings and for SMK3 audit trails.

Detection sensitivity stays in the customer's hands via Sensitive, Standard, and Conservative presets plus per-detection thresholds, balancing false alarms against missed events. All video processing stays inside the warehouse network, retention follows internal policy, access is role-based and logged, and the final judgement always remains with people. Automata Info Nusantara starts with a half-day site survey and a measurable 6–8 week pilot.