How to Identify and Manage Warehouse Hazards

An exploration of AI and technology's transformative role in modern warehousing, featuring insights from a professional with 15+ years of hands-on warehouse experience spanning from forklift operator to multi-facility management.

About the Guest

Justin Emmons is the Lead Implementation Engineer at OneTrack with 15+ years of hands-on warehouse experience, progressing from forklift operator to multi-facility management before joining the technology side.

Key Topics Discussed

AI's Revolutionary Impact

Computer vision and machine learning are fundamentally changing warehouse safety and efficiency, enabling monitoring and insights that weren't previously possible.

3PL vs. Shipper Challenges

Different operational models face different challenges. Understanding the specific context matters for effective solutions.

Leading Safety Indicators

Common hazards that indicate risk:

• Cell phone usage while operating equipment
• Headphone use blocking auditory warnings
• Improper positioning (feet outside compartments)
• Hood wear obstructing peripheral vision
• Distracted driving behaviors

Productivity Challenges

Key operational issues that impact efficiency:

• Equipment idle time and empty-load movement
• Break/lunch transition downtime
• Supervisor task management across shifts
• Off-shift visibility gaps
• Cross-site process inconsistencies

Technology Integration

The platform combines sensor detection, computer vision analysis, and machine learning to create event "fingerprints" for safety and productivity monitoring, achieving approximately 90% accuracy in hazard detection.

Coaching-First Culture

The goal is keeping operators employed and improving, not catching people making mistakes. Data supports development, not punishment.

Key Quotes

"At the end of the day, you want your employees to come in the door safe and leave safe."

"We're fingerprinting each event, comparing against similar events to determine if it's a concern."

"My goal is to keep that operator there, make sure they're aware of the process."

Key Takeaways

1. Experience matters - Understanding warehouse operations deeply informs better technology
2. Leading indicators - Identify risky behaviors before they cause incidents
3. Coaching over punishment - Use data to develop people, not catch them
4. Context-specific solutions - 3PLs and shippers have different needs