The Impacts
Uncontrolled forklift movement and poorly defined work zones posed significant safety and operational risks within the facility. Near-miss incidents highlighted the potential for far more serious outcomes if left unaddressed.
The impacts included, or could have included:
- Risk of serious injury or fatality, resulting from collisions between forklifts and pedestrians
- Unsafe working conditions, increasing stress and reducing confidence among staff on the factory floor
- Operational downtime, following incidents, investigations, or enforced shutdowns
- Significant financial cost, including equipment damage, lost productivity, insurance impacts, and potential regulatory penalties
- Compliance and reputational risk, particularly in relation to workplace health and safety obligations
These risks underscored the need for a proactive, physical control solution to separate vehicle movements from pedestrian areas and create a safer, more predictable working environment.
The Solution
A network of Enta boom gates was installed throughout the facility to physically control forklift and vehicle movement across key internal intersections and work zones. The boom gates create defined access points, ensuring vehicles can only enter designated areas when it is safe to do so.
By introducing controlled stop–go points within the factory, the solution enforces separation between forklifts and pedestrians, reduces uncontrolled movement, and clearly defines safe working zones. The system integrates seamlessly into daily operations, maintaining production flow while significantly improving safety across the site.
The Outcome
The installation of Enta boom gates has significantly improved safety across the CHEP Rochedale facility by clearly separating forklift movements from pedestrian work zones. Vehicle access is now controlled at key internal points, reducing near-miss incidents and creating a more predictable, orderly flow of movement throughout the factory.
Staff benefit from safer, clearly defined work areas, while forklift operators have improved visibility and control when moving between zones. Overall, the solution has reduced safety risk, strengthened workplace compliance, and supported uninterrupted production by proactively managing internal traffic rather than reacting to incidents.