Automated Projection Safety Signage at Terex Warehouse

The Problem

Terex was facing a significant safety challenge at its warehouse, where a doorway opened directly onto a busy forklift route. This hazardous layout resulted in at least one near miss incident per week.

The client had attempted to mitigate the risk by installing a physical barrier just beyond the door to prevent pedestrians from stepping straight out and had also placed basic static signage on the door itself.

Despite these efforts, the weekly near misses continued, highlighting the need for a more effective, dynamic warning system to protect both pedestrians and operators.

The Solution

WSS recommended and implemented a proactive projected safety signage solution. The system was designed to activate only when needed, enhancing its effectiveness.

Specifically, a projector was installed and calibrated so that whenever a forklift approached within five metres of the doorway, a highly visible warning symbol and message were instantly projected onto the floor on the pedestrian side of the door.

This provided a moving visual alert that a forklift was approaching, effectively capturing the attention of anyone about to exit and giving them clear, immediate warning to stop and check before proceeding.

The Result

The installation was completed in February 2024. From that date up to August 2025, the area has experienced a complete elimination of near miss incidents.

The projected warning system has successfully prevented any further dangerous encounters, transforming a previously high-risk zone into a demonstrably safer environment for all warehouse personnel.