Accidents in Logistic Vehicle Loading Areas and Prevention Methods via Artificial Intelligence

Factory and warehouse loading areas are among the most critical yet least visible links in the production chain. The rush to prepare shipments quickly from the manufacturer and the pressure on the logistics firm to dispatch vehicles on time create significant time constraints on personnel working in these areas. This speed-focused environment often leads to neglecting fundamental safety steps. While forklifts are transporting products, employees may wander around uncontrolled, loading might start before the vehicle is properly docked, or wheel chocks may be forgotten. These seemingly simple acts of negligence can escalate into serious accidents or even fatalities within seconds. These loading zones are one of the most misleading areas when it comes to the perception of safety—“if no danger is visible, it must be safe.” In reality, a truck not properly docked, an employee in a forklift’s blind spot, or failure to follow company procedures during tarp fastening are common causes of severe past incidents. Every year, hundreds of injuries and fatalities occur globally in such loading/unloading areas alone. Although occupational safety procedures are mostly defined on paper, adhering to these rules within the fast pace of daily operations is often not feasible. So, what’s the solution? A system that never loses focus—even when human attention fails, tires, or overlooks something: Artificial intelligence technologies. In this blog, we will comprehensively explore the causes and statistics of accidents in loading areas and how AI-based systems can help prevent them.

Root Causes of Accidents in Logistics and Warehouse Areas and Suggested Solutions

The transportation sector is one of the industries with the highest number of occupational accidents based on time lost to injury in Turkey. After the construction industry, it also ranks high in fatal work accidents. Intense workloads, use of heavy machinery, and human factors are the main contributors to accidents in logistic depots and loading zones. Primary causes of accidents include:

• Inadequate training and improper use of equipment,
• Intense, rushed work pace due to tight delivery deadlines,
• Lack or misuse of personal protective equipment (PPE),
• Incorrect use and insufficient maintenance of heavy equipment like forklifts,
• Slippery and disorganized work areas, poor lighting and lack of visual cues,
• Fatigue and distraction caused by long working hours,
• Communication breakdowns between operators and field workers,
• Disorganized stacking of materials,
• Adaptation problems to new technologies.

To minimize these risks, areas must be inspected regularly by experts, and immediate action must be taken for identified issues. However, delays caused by cost-saving excuses create an ongoing risk of accidents.

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Occupational Safety with Image Processing and Smart Systems

In Turkey, approximately 15,000 occupational accidents are reported annually in the transportation and logistics sectors. While some of these result in injuries, unfortunately, many also result in fatalities. Globally, the number of work-related accidents in the logistics sector is much higher, with over 20,000 fatal incidents reported annually. Most of these accidents involve slipping or overturning due to improper docking, vehicle movements caused by incorrectly placed wheel chocks, squeezing or crushing due to unauthorized human presence in loading zones, collisions with employees in forklift blind spots, PPE deficiencies, and falls during tarp fastening in windy conditions. For example, in an incident in Istanbul, a truck that was not properly docked moved due to the absence of wheel chocks and seriously injured a worker. Such risks can be significantly reduced with advanced AI technologies. These systems can continuously monitor proper vehicle docking, chock placement, human presence in filling areas, safety around forklifts, PPE usage, and the number of people on a vehicle, intervening before danger occurs. As a result, workplace accidents decrease, and the culture of occupational safety is reinforced and sustained.

Blind Spots Around Trucks and Image-Based Human Detection Warning Systems

Truck maneuvering areas—especially in logistics centers and factory loading zones—pose the highest risk. One of the main reasons is the many blind spots around trucks. Drivers often cannot see the front, rear, and especially the rear-right sides of their vehicles. These blind spots widen further during maneuvers such as reversing or adjusting position, putting nearby individuals in danger without being noticed. Traditional mirrors or human oversight may not suffice. Therefore, modern safety solutions are essential. At this point, AI technologies come into play, closing this safety gap in the field. Risk Zone Monitoring via Image Processing: AI systems can continuously scan the surroundings of trucks preparing to dock in logistics storage areas using cameras. These systems can automatically detect human presence, especially in blind spots, and send real-time alerts to operators or drivers. Advanced AI models don’t just detect humans—they also analyze motion direction, speed, and other variables to predict possible collisions or entrapments. With this technology, the following actions are possible:

• Human presence is checked before a truck docks.
• If people are detected in blind spots, visual and auditory alert systems are triggered.

This approach not only reduces workplace accidents but also provides a safer environment for employees, strengthening the safety culture both technically and humanely.

Wheel Chock and Docking Control with Image Processing

In logistics areas, vehicles must dock fully, safely, and aligned. However, many accidents stem from deficiencies during the docking process. Trucks may not reverse properly to the ramp, or may shift laterally, posing major risks to forklift operators during loading. In addition, failure to place or misplacing wheel chocks can cause a truck to move unexpectedly during loading. This may require the forklift to leave the vehicle and reapproach the ramp or cause balance loss for the operator—posing high risk to both personnel and equipment. Benefits of AI systems in this context include:

• Detecting whether the truck aligns perfectly with the designated docking line,
• Automatically recognizing if wheel chocks are correctly placed,
• Alerting when unusual gaps exist between the vehicle and ramp,
• Taking instant precautions in cases of overhang or forklift fall risks.

Each approaching vehicle is dynamically analyzed, and if safety conditions aren't met, the operator is notified before loading begins. This helps prevent both material and human losses.

Forklift–Human Interaction in Logistics Areas

Time pressure is a constant factor in logistics operations. While manufacturers aim to dispatch goods quickly, carriers strive to minimize waiting times on site. This increases the pressure on forklift operators, often prompting them to move faster and take riskier maneuvers. In such a high-paced environment, pedestrian presence—especially personnel from production or quality departments—becomes a frequent source of accidents. Given the limited visibility of forklifts, manually detecting humans is not always possible. To eliminate these risks, AI-supported forklift–human interaction monitoring systems can be deployed. These systems:

• Perform real-time analysis using AI when human presence is detected around forklifts,
• Trigger visual and auditory alert systems when risky proximity is identified,
• Additionally provide automatic slowdown and stop functions for electric forklifts.

Even if the operator unknowingly heads toward a danger zone, the system intervenes to prevent potential collisions. These systems ensure both human safety and uninterrupted, secure logistics operations.

Tarp Fastening Safety Checks with Image Processing

After loading, especially in open-bed transport vehicles, covering the load with a tarp is critical for both transport safety and product integrity. However, this phase is also among the most accident-prone. The reason is simple: Humans working on a high, unstable platform. Workers often have to climb onto the truck or trailer to fasten the tarp, which introduces several risks:

• Fall risk: It's hard to maintain balance on the trailer. A sudden gust of wind, slippery surface, or tarp movement can cause falls,
• Lack of PPE: Not wearing helmets or failing to use safety ropes can make falls deadly,
• Weather conditions: In windy weather, tarps can whip around, causing workers to lose control.

AI technologies can conduct several safety checks in such critical zones:

• Detect whether the worker fastening the tarp is wearing a helmet,
• Visually confirm if a safety rope is attached,
• Automatically count how many people are on the vehicle,
• Monitor wind sock indicators to determine if wind has reached dangerous levels, prompting a halt or system alerts.