4 Forklift Mistakes to Avoid with RTLS (Real-Time Location System)

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Forklift mistakes in warehouses are common, and even though not all of them lead to injuries, they can cause detrimental consequences. The warehouse may need to cover costly repairs, suffer time wastage, loss of inventory, and others. The good news is that there is a technology that has come up to reduce these mistakes. RTLS technology provides better insights and visibility and tracking forklift activity to avoid this bottom line. Forklift misuse and accident can bring a huge impact on your operations. According to a study conducted by the NSC in 2019, 79 forklift deaths and more than 8,000 injuries were accounted for and these incidents amounted to hefty costs. In this article, we will discuss 4 forklift mistakes and how RTLS technology helps to avoid them. Read on to find out more.

Incorrect Upload

With a large inventory in a warehouse, it is easy for a forklift to pick the wrong item. RTLS comes to the rescue by ensuring the operator can view their tasks in real-time. The forklift comes with a screen that the operators can look through to know where their pick up is, the right route to use, and where to unload it. The navigation directs the operator through the shortest and fastest route based on blockers and traffic.

Our Litum RTLS allows an alert when the operator is about to drop the item on the wrong destination and this prevents incorrect unloading. A UWB- powered RTLS solution provides a high level of accuracy, and this is effective in harsh conditions where a pallet must be placed in an exact position.


In a warehouse or a large industry, people and forklifts are always in a rush in the daily operations to ensure they remain on schedule. This rush often results in accidents, some of which can be fatal. When an accident happens, it impacts the overall worker morale, health, and increased costs of repairs. The only solution is to find ways of preventing collisions from happening.

According to OSHA, 70% of forklift accidents experienced can be evaded by providing the right solutions. An RTLS employee tracking technology can help to track the exact location of an employee and where everyone is moving in real-time. This way, the forklift can automatically slow down when approaching an employee or close to the crossroads. The anti-collision RTLS system helps to prevent forklift-employee and forklift-forklift collisions. It monitors the movement of equipment and workers and warns of an imminent collision. It does this by measuring the distance between forklifts and workers and alerts when it detects a risk. An RTLS forklift tracking system can tell when a driver is going at a dangerous speed, when a driver makes an unsafe turn, or when someone untrained attempts to drive the forklift.

Access to Banned Area

Without a system to indicate banned areas, forklifts will always find their way to these areas. Banned areas like near entrances of safety zones must be indicated to ensure forklifts do not access them. Our UWP-enabled system from Litum offers indoor tracking that allows to create several zones. The system gives the warehouse manager full control of these areas and warns the drivers to avoid the banned zones. A forklift operator can also be able to alert another guest like a truck driver when they step into their operation zone to help prevent accidents and injuries. This warning is not only based on position but the speed of driving too. This system helps to increase observance, prevents forklift damage, and improves general workplace safety.

Collapsing Shelves and Racks

Collapsing racks and shelves are another leading factor in warehouse injuries and accidents. This mostly happens when a mispositioned item did not fall initially after being hit. The item is left unstable and might fall on a worker. A forklift fitted with our RTLS technology is able to detect shock and send the signal to the team on maintenance. The team can then know the exact source of the shock and the strength and take immediate action to fix it. This helps to prevent injuries and property damage. Additionally, with RTLS, it becomes easy to record the exact location and time when the collapse occurred.


RTLS systems can help create a risk-free environment in warehouses and large industries. The sensors fitted on the equipment can provide insights into where a pedestrian is and how a driver is operating a forklift. What RTLS solutions do is not only to prevent accidents and misuse but also to improve overall efficiency. Using UWB-enabled tags, operators can track employees and assets in real-time. The tracking allows supervisors to build a safe zone that alerts operators of hazards in real-time.

In short, Litum’s RTLS technology provides insights and visibility on employees and assets at all times. It helps prevent the forklift accidents mentioned above, keeping the workplace safe.