Retail and Warehousing

Business: Retail and Warehousing

Industry: Warehousing

Location: Multiple locations, Victoria    

Forklift LED Red Zone Danger Warning Light


Warehousing is a critical business process and a growing industry in itself. As a business process, warehousing involves the tracking of products and manufacturing resources, providing the management with real-time understanding and appreciation of the current products and goods in stocks, the fast-moving items and those that are not performing, as expected. Recent trends in warehousing point to automation, where products and pallets travel through automated cranes and conveyor belts. The trend may point to automation, but the majority of business owners in Victoria, Australia still rely on the traditional approaches to warehousing, including the use of warehousing machines and equipment including forklifts.

Our client with multiple retail store locations in Australia relies partly on traditional warehousing approaches through the use of forklifts. Also known as lift trucks or forklift hydraulics, these warehousing equipment units are controlled by electrically-controlled actuators or through the use of levers that directly manipulate the valves. Aside from its capability to raise and lower the forms or blades, the forklift operator can also tilt its mast to avoid fork slipping. This tilting ability also allows the operator to work on uneven pavements. And for the longest time, the forklift operators of the company have been trained in the safe and efficient way of handling the forklifts. Unfortunately, even with a presence of a committed set of forklift operators, accidents can happen. And the incidence of accidents and work interruptions on the production floor are further boosted by the absence of safety devices and controls like a LED red zone danger warning light for forklifts.


As a retail company carrying a comprehensive set of products from computers to furniture and kitchen appliances, the management maintains a number of warehouses manned by forklift operators. It is the job of the operators to move pallets and boxes, and stack them in specific locations, at various heights. Due to the nature of the tasks and the presence of other workers and employees on the floor, a number of injuries and accidents have been reported involving its fleet of forklifts. Just last year, an accident was reported in one of its warehouses, where one of its forklifts struck an uneven pavement, causing the pallets to fall on one of the employees. Based on filed reports, the employee suffered minor injuries but were unable to complete light duties without feeling some pain. A more serious accident was also reported last year when a worker was run over by a busy forklift. Police reports indicated that the worker was pinned by the forklift, and a jack was used to raise the equipment to free the body. It was not lethal, but warranted hospitalization for a few days. This resulted in lost productivity, medical expenses and concerns for safety in the workplace. These two incidents are avoidable if only the right safety devices and accessories like a LED red zone danger warning light for forklifts are in place.


As part of its Health and Safety Program, we coordinated with its safety committee and the HR department to suggest ways on how to prevent these accidents from happening. On top of the proposed refresher course on forklift handling and safety, we recommended the installation of a LED red zone danger warning light for forklifts which can serve as a visual reminder for the operator and the employees working near the lift. As one of the safety accessories carried by Reverse Safe, the warning light is made with durability in mind, using die-cast aluminum allow housing. It’s designed as an energy-saving LED light, which means that it saves most of its power compared to traditional bulbs. For this specific project, our team used two lights and these are mounted on the rear and the front of the forklift. Brackets were used to confidently secure the LED lights on both ends of the forklift. After mounting the lights, a member of our maintenance team wire the LED lights into the power source of the forklift. The exact connection of power will eventually depend on the specific forklift model.

Creating a visible zone of danger for improved safety

With the installation of two LED lights on both ends, the forklift casts a red warning light around the unit, creating a visible zone of danger. As soon as pedestrians and the other workers on the production floor notice the presence of this visible red zone, they will stay behind, or remain on the sides. With the lights on, workers within the area are informed of the danger, ultimately keeping them safe and free from injuries. The red light is also helpful when the forklift is reversing and the workers around it failed to hear the sound. The moving red light will serve as a visual cue that indeed, the forklift is reversing and they need to stay in the safe zone. And this is exactly what happened in the warehouses of our client. Most of it forklifts are now installed with the LED danger warning lights, effectively reducing the incidence of accidents in the workplace.

With these safety and warning devices, workers and employees can easily see if the forklift is reversing, allowing them to act appropriately. This also promotes a ‘safe zone’ where the lifts can operate, improving productivity along the way.