How a Regional 3PL Eliminated Forklift Incidents, Passed OSHA Inspection, and Recovered $410,000+
The Challenge
A regional 3PL logistics hub — 280,000 sq ft, 48 existing IP cameras — had zero visibility into live operations. Two OSHA recordables in 18 months from forklift incidents. Supervisors spent 3+ hours per shift reviewing footage after incidents. Inventory shrinkage running at 4.2% with no identified source.
What VivyaSense Found — First 30 Days
- 1
Forklift–pedestrian proximity violations: 19 per shift in Dock B — a "restricted" zone that was never enforced.
- 2
11 workers per shift in forklift areas without required high-visibility vests — a direct OSHA 1910.178 willful violation exposure.
- 3
2 receiving dock doors left unsecured after hours — identified as the primary inventory shrinkage source across 3 separate audit trails.
- 4
Night shift picking aisles: 22% idle time between 11 PM–1 AM, directly correlating with persistent next-day SLA misses.
Results — 90 Days
- ✓
Forklift–pedestrian conflicts: ▼ 91% → Zero recordable incidents in 90-day period
- ✓
PPE compliance: 61% → 94% across all monitored zones
- ✓
Inventory shrinkage: 4.2% → 1.8% → $238,000 in recovered annual value
- ✓
Night shift idle time: ▼ 34% → 1.6% throughput increase on outbound shipments
- ✓
OSHA inspection: Week 11 — Zero citations issued → Timestamped VivyaSense data presented as proactive compliance evidence
ROI Summary
“We thought our cameras were giving us coverage. VivyaSense showed us they were just recording problems we'd never find until someone got hurt. That's a completely different thing.”— VP Operations, Regional 3PL Provider