Working with a leading motor vehicle manufacturer, which operates a large assembly plant across the UK and Europe with over 1,000 employees. The facility produces a variety of vehicle parts, with complex workflows involving heavy machinery, forklift trucks, and pedestrian traffic. Over the past year, the company noticed an increase in near-miss incidents involving pedestrian and vehicle interactions, particularly in areas where visibility was limited. This raised concerns about worker safety and prompted a review of their existing health and safety signage and practices. From initial contact and discussion about the issues they were facing, we quickly arranged a site visit to survey the facility, gaining knowledge of the signage requirements and where we could provide a solution - 

Challenges Identified Upon Site Visit

1. Inadequate and Damaged Signage: The existing signage and floor markings in the plant were damaged and faded, poorly positioned, and often not visible enough due to low lighting or obstruction by equipment. Signs indicating pedestrian crossings and walkways, vehicle routes, and hazardous areas were particularly hard to see.

2. Complex Traffic Flow: The plant's layout had evolved over time, leading to complex traffic routes where vehicles, such as forklifts and delivery trucks, frequently crossed paths with pedestrian walkways and were blocked from sight behind roller doors.

3. Low Awareness of Safe Routes: Workers, especially new employees, found it difficult to navigate the plant safely, resulting in frequent breaches of safety zones and confusion about right-of-way.

4. Cost and Business Downtime: Traditional signage which included vinyl and painted signs were costing our customer time and money to replace frequently due to damaged floor markings and faded safety signage which was highlighted in a health and safety report.

Solution: Projected Signage for Pedestrian and Traffic Management

Our customer decided to overhaul its warehouse signage and traffic management system to improve safety and reduce the risk of accidents. The project involved several key steps:

1. Comprehensive Risk Assessment: A detailed risk assessment was conducted in accordance with the Management of Health and Safety at Work Regulations 1999. This identified high-risk areas where signage visibility was poor due to damage or blind spots and where pedestrian and vehicle interactions were most frequent.

2: Design and Placement of New Signage:

-High-Visibility Signage: The company installed new high-visibility virtual signs using LED Projectors to display clear and larger fonts. These were placed at key points, such in front of roller shutters which divided vehicle routes and pedestrian walkways across high traffic areas.                                                   

-Durable Floor Markings: Projected Signage was added to pedestrian-only zones and vehicle-only lanes, using durable, ultra bright LED projectors to ensure they remained visible over time and could not get damaged by heavy machinery like forklifts.

-More Visible Signs: In low-light areas, illuminated floor safety markings were installed to ensure visibility at all times. Projected signs with motion sensors were also introduced, alerting both pedestrians and forklift drivers of approaching traffic and footfall.

3. Traffic Flow Redesign

-Separate Pedestrian and Vehicle Routes: Where possible, pedestrian routes were redesigned to avoid crossing vehicle paths. In areas where separation was not possible, elevated walkways or barriers were introduced to physically separate pedestrians from vehicles.

-One-Way Systems: To reduce the likelihood of collisions, one-way systems for vehicles were introduced in narrower parts of the building. This reduced the number of potential conflict points and simplified traffic flow.

4. Employee Training and Awareness of Visual Colour Coding

-Safety Workshops: Regular safety workshops were held to train staff with the new signage system including specific colour coded areas and traffic routes. Special emphasis was placed on new employees, ensuring they understood the plant's layout and the importance of adhering to colours along designated pathways.                                                              

-Ongoing Communication: The health and safety team implemented a communication strategy that included regular reminders about the importance of following the new signage colour system, using posters, digital displays, and regular staff training.

5. Monitoring and Continuous Improvement

-CCTV Surveillance: The company implemented ongoing CCTV surveillance to monitor the effectiveness of the new system and identify any areas for improvement. This included regular inspections of the health and safety signage and traffic management system, and gathering feedback from workers.             

-Incident Reporting: A more robust incident reporting system was introduced, encouraging workers to report any near misses or concerns related to traffic management. This data was used to make further adjustments to the safety signage and warehouse layout as needed.

Results and Benefits

1. Reduction in Near-Miss Incidents Within six months of implementing the new health and safety signage and traffic management system, our customer reported a 26% reduction in near-miss incidents. The clear, high-visibility projected signage helped both pedestrians and drivers navigate the plant more safely, reducing confusion and the likelihood of accidents.

2. Improved Worker Confidence and Compliance Workers reported feeling more confident in navigating the plant, with 85% of surveyed employees indicating that the new virtual signage made them feel safer at work. Compliance with designated pathways increased, as workers found it easier to follow the clearly marked routes.

3.Enhanced Visibility in Low-Light Areas The introduction of illuminated and projected signs significantly improved visibility in low-light areas, particularly during night shifts or in parts of the plant with poor natural lighting. This reduced the risk of accidents in these previously problematic areas.

4. Ongoing Safety Culture Improvement The project contributed to a broader culture of safety within the plant. The company saw an increase in the reporting of potential hazards, which allowed for continuous improvement of safety measures.

5. Compliance with Health and Safety Regulations By proactively addressing the risks associated with poor signage and traffic management, our customer ensured compliance with key health and safety regulations, such as the Provision and Use of Work Equipment Regulations 1998 (PUWER) and Workplace (Health, Safety and Welfare) Regulations 1992. This helped avoid potential fines and legal issues, while also protecting the company's reputation.

Conclusion

This case study in the motor industry demonstrates how improving and switching to projected safety signage for traffic management can significantly enhance safety in a large motor manufacturing plant. By addressing the visibility and clarity of safety signs, redesigning traffic flow, and fostering a culture of safety, the company was able to reduce the risk of accidents, protect its workforce, and comply with stringent health and safety regulations. This approach serves as a model for other companies in the motor industry and beyond looking to improve workplace safety through practical, effective measures using our projected safety signage solutions. 

For more information get in touch today by visiting www.projectedimage.com or email gobo@projectedimage.com.