Rotterdam Distribution Hub Cuts Forklift Incidents by 58% Across 56 Cameras
The Challenge
A major distribution hub in the Rotterdam port area, Netherlands — 56 cameras covering 45,000 m² of warehouse floor, loading docks, and MHE traffic lanes — managed 380 workers across 2 shifts. The facility experienced a high forklift-pedestrian near-miss rate with no automated detection. EU ATEX compliance concerns persisted in chemical storage zones. Manual incident reporting was missing more than 60% of actual safety events, leaving the operation exposed to regulatory action and preventable injuries.
What VivyaSense Found — First 30 Days
- 1
Forklift-pedestrian near-misses at aisle intersections: 26 per week across the 45,000 m² warehouse floor — none triggering any alert or log entry. Highest density at cross-dock transfer zones during shift overlap.
- 2
Loading dock safety violations: 19 instances per week of workers entering active dock bays without lockout/tagout confirmation — trailer creep risk completely unmonitored.
- 3
Chemical storage zone PPE gaps: 31% of entries into ATEX-classified zones lacked required respiratory protection or anti-static footwear — a direct EU compliance exposure.
- 4
Unreported incidents: Manual reporting captured fewer than 40% of actual safety events — 14 forklift tip-overs and 8 pallet rack strikes in 30 days went entirely undocumented.
Results — 12 Weeks
- ✓
Forklift-pedestrian incidents reduced by 58% — real-time proximity alerts at 12 high-traffic intersections enabled immediate speed reduction and route separation enforcement
- ✓
Loading dock compliance reached 97% — automated lockout/tagout verification alerts eliminated unauthorized bay entries within 6 weeks
- ✓
EU ATEX audit readiness achieved — continuous PPE monitoring in chemical zones produced full compliance documentation, passing external audit with zero findings
- ✓
Insurance premium reduced by €42,000 annually — documented 58% incident reduction and automated reporting enabled renegotiation with underwriter
ROI Summary
“Our forklift safety culture changed completely within weeks. VivyaSense gave us visibility we never had — every near-miss, every PPE gap in the ATEX zones, all documented automatically. Our EU compliance auditor called it the most thorough safety evidence package they'd ever reviewed.”— Logistics Safety Manager, Distribution Hub, Rotterdam