RCT – Powered by Epiroc is helping transform warehouse safety at one of Australia’s leading logistics providers with the successful deployment of its advanced Pedestrian Alert System (PAS).
The client identified increasing safety risks within its warehouse and distribution environments, driven by higher activity levels, mixed materials handling equipment (MHE), and frequent pedestrian interaction.
Determined to proactively address these challenges, the company’s National Asset Manager initiated a comprehensive evaluation of emerging safety technologies, seeking a solution that could deliver real-time, highly accurate pedestrian detection without disrupting operations.
Warehouse environments are inherently complex, with forklifts, reach trucks, and other equipment operating in close proximity to personnel at all times.
Despite robust safety protocols already in place, the business experienced a rise in near-miss incidents and identified limitations in traditional controls such as signage, barriers, and high-visibility PPE.
In addition, most existing detection technologies trialled proved inconsistent in high-traffic, dynamic environments, highlighting the need for a more reliable and scalable solution.
A nationwide trial was therefore conducted across high-activity sites, assessing a range of technologies including wearable solutions, tag-based proximity systems, and AI-driven camera detection, which included our Pedestrian Alert System (PAS).
Each solution was evaluated against key operational criteria, including detection accuracy, reliability, false alert rates, ease of integration, and operator usability.
Following extensive testing, our PAS emerged as the clear leader.
“The solution demonstrated exceptional real-time detection accuracy, with zero false positives recorded during trial periods, eliminating unnecessary operator distraction,” said RCT’s Industrial Global Business Development Manager, Nigel Goode.
“It also delivered consistent performance across diverse environments, including high-density traffic zones, while offering seamless integration across mixed Material Handling Equipment fleets,” he added.
Based on the successful trial, the logistics provider has formally adopted RCT’s PAS as its exclusive pedestrian detection solution.
A phased rollout is now underway across its national network, prioritising high-risk sites and facilities with elevated levels of pedestrian and equipment interaction.
The system is being deployed across a wide range of equipment, ensuring consistent safety standards across all operations.
“The PAS system’s ease of installation and configuration has further supported rapid deployment without impacting operations,” he added.
The adoption of PAS will significantly reduce near misses and potential incidents while improving operator awareness and response times.
“It also reinforces a strong safety culture and supports the company’s commitment to achieving zero harm across its operations,” he said.
This initiative marks an important step forward in leveraging advanced technology to create safer, smarter warehouse environments.
###
For media enquiries, please contact:
Emma Young, RCT Communications Officer
This year marks a truly significant milestone for RCT – Powered by Epiroc and its flagship industrial fleet management system, SmarTrack. It's a moment to reflect on how far we've come and the role we've played in shaping fleet management and safety technology as it exists today.
RCT's journey began with early machine telematics, focused on operator authentication and the collection of critical operational data. At the time, these capabilities were groundbreaking, laying the foundation for smarter, more accountable fleet operations. In true RCT style, we continued to innovate to improve the system and continue to meet clients' needs.
Therefore, not long after, we introduced operator user interfaces to further streamline interactions between humans and systems. Of course, when this was first developed, it was simple by today's standards, but revolutionary for its time.
It was a basic LCD display, featuring just three rows, containing up to 20 characters. Just enough information on the screen to display information required for operators to complete electronic pre-start checklists that could be centrally managed through an online portal.
This was an early, yet significant step towards digitising processes that were once entirely manual.
Driven by relentless innovation, these early concepts provided the cornerstone of the evolution of what we know as today's world-class SmarTrack - a renowned solution in the materials handling industry. This state-of-the-art solution has now been deployed globally, and SmarTrack represents decades of refinement, real-world testing, and continuous improvement.
Early adopters such as a well-known packaging and recycling company, played a pivotal role in validating the technology and accelerating its adoption, helping to shape the platform into what it is today.
In parallel, we were also pioneering advancements in fleet safety. One of the most notable breakthroughs was the introduction of forklift GPS Zoning. By allowing companies to draw operational zones directly on Google Earth maps and integrate them with RCT's Speed Limiter technology, businesses gained unprecedented control over vehicle speeds and site safety. Industry leaders like a major Australian integrated steel manufacturer, were among the first to embrace this innovation.
Today, terms like zoning and geofencing are commonplace across the industry, but two decades ago, they were anything but. These solutions didn't just improve efficiency; they fundamentally changed how organisations approached safety in dynamic operational environments.
As we mark this 20-year milestone, it's not just the technology we celebrate, but the vision, persistence, and partnerships that made it possible. RCT's legacy is one of innovation driven by real-world challenges and most importantly a commitment to building safer, smarter operations alongside our customers.
To learn more on these technologies, visit our landing pages:
The challenges surrounding safety and operational efficiency in the supply chain industry are ever-present. With forklifts and personnel sharing the same working space, the risk of accidents and fatalities remains high. Therefore, the necessity for innovative solutions that ensure everyone’s safety is mandatory, and a bonus that these solutions also optimise operations at the same time.
Incidents in the industry serve as stark and timely reminders of the potential hazards associated with supply chain operations. For instance, the recent tragic accident involving a forklift operator in Australia underscores the critical need for stringent safety measures.
Despite the operator having a high-risk work license and recent safety training, an unfortunate lapse resulted in a fatal outcome. This illustrates the need for robust safety protocols and advanced technology to prevent such accidents.
Earlier in the year, SafeWork NSW had launched a statewide compliance operation aimed at reducing injuries caused by mobile plant, fixed machinery, and vehicles in the workplace. To date, this operation has already resulted in over 140 notices being issued, with a significant focus on forklift safety, including managing risks such as pedestrian separation, rollover and collision prevention, and ensuring proper maintenance and inspection protocols.
At RCT, safety is our top priority. Our innovative technology is versatile and can be installed on any machine, regardless of make or model. Forklift-related incidents can be a thing of the past with some of the following solutions:
RCT’s SmarTrack Fleet Management system is essential in offering a comprehensive approach mitigating risks. From monitoring, controlling, and optimising the use of forklifts, it integrates real-time data and advanced analytics to provide operators with invaluable insights into each forklift’s performance and status. This enhances operational efficiency and enables proactive maintenance, reducing the likelihood of equipment failure and accidents.
One of the most significant advancements in supply chain safety is the implementation of RCT’s Pedestrian Alert Systems (PAS). Designed to detect and alert operators to the presence of personnel near forklifts, this system prevents accidents before they occur by providing awareness. Utilising state-of-the-art sensors and communication technology, the PAS ensures operators are always aware of their surroundings, significantly reducing the risk of collisions and enhancing overall site safety.
The supply chain industry faces unique challenges that require innovative solutions. RCT’s SmarTrack Fleet Management and Pedestrian Alert System can be combined into one integrated solution, delivering full coverage for these challenges and offering a safer, more efficient, and cost-effective way to manage supply chain operations.
Ready to invest to further protect your workforce and stay ahead in an increasingly competitive industry? With a comprehensive global support team, we’re ready to hear from you. Enquire now at xxxxxxxxx@xxx-xxxxxx.xxx
Safety is paramount for national printing specialist, Ovato who have successfully utilised RCT’s Muirhead® Speed Gates solution at its warehouse operations in Western Australia.
Muirhead® Speed Gates automatically reduces an industrial machine’s speed depending on pre-determined speed restrictions across a logistics site.
Meaning that regardless of operator input this product effectively enforces speed limits in yards, inside warehouses and common pedestrian areas.
The technology is mounted above warehouse entrances/exits and racking aisles and communicates with Machine Location Tags fitted to the roof of equipment such as forklifts and reach trucks.
Ovato WA Logistics Manager Mark Mead said their operation uses a fleet of Toyota forklifts including plain models and machines with clamp and grab capabilities.
He said since being installed the Speed Gates have worked well and the site has not recorded any incidents.
“I have had no reports from anybody on site about any issues or problems so I would say they have definitely been a success at this location,” he said.
“The product is pretty much set and forget so the staff are aware it is there and when driving the forklifts you notice the change in speeds when you drive around inside the warehouse and then move outside.”
Mr Mead said they sought to install Speed Gates to improve safe forklift operations and ensure compliance with safety policies.
“Similar to how we have speed limits for cars onsite it is important we have the same rules with forklifts,” he said.
“If you are carrying a two-tonne load then you want to have confidence that you are in control of the machine’s speed so it makes sense to have Speed Gates for sure.”
American materials handling dealer Equipment Depot is thrilled with the success of its latest project with smart technology specialist RCT, which has seen the successful rollout of forklift seatbelt safety solutions.
Recently, Californian-based specialists with Equipment Depot approached RCT’s Industrial Account Manager Nikolas Walden to provide an operator safety solution to fit to two new Cat forklifts for their customer.
RCT subsequently provided its Muirhead® Sequential Seatbelt Controller (SSBC) which requires forklift operators to act in a particular sequence – sit down and engage their seatbelt – to activate the machine.
The solution is designed to immobilize the forklift until the operator is sitting and the seatbelt is engaged.
Equipment Depot Account Manager Oliver Bragg said their customer requested the additions to their new forklifts to safeguard their operators.
“As the trucks were in our inventory we had to find an alternative source rather than order (fitted out forklifts) from the factory,” Mr Bragg said.
“I spoke with Nikolas and he advised me on how easy (the Muirhead® Sequential Seatbelt Controller) is to retrofit onto an existing unit.”
“Nikolas shipped the product right away and provided my technicians with information on how to install it.
“The units were delivered to my customer and they loved how the system performs. They like the reassurance that the operators have to purposely bypass the system in order not to wear a seatbelt and this allows them to keep their operators accountable.”
“Thank you to RCT and Nikolas. I will be using you again for many more business deals.”
Mr Walden said RCT is very pleased to supply Equipment Depot with quality industrial technology that meets their needs.
“Our products are specifically designed to retrofit with any type of equipment regardless of their age, make or model and proved to be an ideal solution to this particular situation,” he said.
“This product will protect workers in the course of operating the forklift fleet and ensure they are working inline with company-mandated policies and safety laws.”
RCT’s Muirhead® Speed Gates solution is revolutionising safe machine fleet practices across logistics and warehousing sites.
Speed Gates ensure all industrial machines – such as forklifts and reach trucks – are travelling at an appropriate speed for its surroundings.
The system is easily deployed at entrances and exits within materials handling facilities and caps maximum speeds on any piece of industrial equipment passing through the zone.
A worksite may be set up to include four safe speeds per site ensuring the materials handling equipment can only travel at designated speeds within defined locations.
The Speed Gate system consists of a gate located above entrances and exits which communicate with a Machine Location Tag mounted on or close to the roof of an industrial machine.
The Machine Location Tag then communicates with a Muirhead® Speed Limiter to manage the speed of the machine.
Additionally, depending on machine type, the Speed Gates may be able to interface directly with OEM speed limiting features.
RCT Product Manager Mick Tanner said the system will effortlessly enable safer materials handling operations.
“Speed Gates will ensure machine operators are fully compliant with site-specific speed limits and keeping in-line with government safety regulations,” he said.
“Improved speed control within your warehouse will reduce the chance of accidents and protect machine operators and other workers.”
“The system is simple to install and requires no ongoing maintenance essentially the system is set and forget.”
“The system can be applied to any type of materials handling equipment regardless of manufacturer so is ideal for both large and small sites that operate mixed fleets.”
RCT has so far received positive feedback from fleet managers at sites which have been using Speed Gates.
Managing mobile equipment fleets across New Zealand’s winemaking industry has never been easier thanks to the hard work of Blenheim-based Forklift Hire Services and smart technology specialist RCT.
The partnership has seen Forklift Hire Services deploy RCT’s market-leading fleet management system SmarTrack® Global to materials handling equipment used by wineries across the country.
Operations Managers can now access data from their entire fleet across multiple sites via one platform with the system's global reporting capability.
A high level of safety, compliance and acceptance are achieved at operations using the latest in fleet management technology with functions such as GPS Zoning, multilingual interfaces, pre-and post-start checklists, operator logins, speed, weight and belt buckle monitoring, impact reporting and message notifications.
Forklift Hire Services Managing Director Jonny Orr said they have deployed 20 SmarTrack® Global units to numerous pieces of industrial equipment over the last 12 months.
“We applied SmarTrack® Global to a variety of petrol and electric machines such as 24v and 80v equipment including forklifts, scissor lifts, knuckle booms and a container handler,” Mr Orr said.
“SmarTrack® Global’s ability to integrate with all brands and equipment types makes it a perfect solution for our customers who wish to supervise every machine in their very diverse fleets.”
Forklift Hire Service’s clients in the winery industry typically utilise their industrial equipment in barrel halls and on bottling lines and for the loading and unloading of trucks which takes place both indoors and outdoors.
“Primarily, our clients seek the operator login function, pre-start checklists for OSH compliance purposes and being able to set alerts for impacts, service reminders and expiring forklift licenses, which is crucial to remain in line with New Zealand’s safety laws,” Mr Orr said.
“Our clients know the product can clearly identify operator habits and incidents which enables managers to implement policies to reduce wear and tear on the machine fleet.”
“From our own perspective as a hire company we work across different businesses and industries and SmarTrack® Global can adhere to the different OSH business systems, so we really enjoy how flexible the system is.”
“The system provides us with real-time notifications alerting us when our hire equipment needs servicing meaning it is easy to be fully across the status of each of our machines at all times.”
RCT Account Manager – Industrial Nicholas Noorman said SmarTrack® Global provides information in relation to ‘events’ that at can highlight areas such as training, environmental hazards, and machine application.
“The SmarTrack system increases the level of responsibility and ownership on the operator, thus reinforcing a positive safety culture,” he said.
Mr Noorman said the work with Forklift Hire Services demonstrates how versatile the fleet management system really is.
“Regardless of the industry you are in or the diversity of your mobile equipment fleet SmarTrack® Global can provide you the information needed to enhance your operation.”
“This work is just the latest successful deployment of SmarTrack® Global to a mobile equipment fleet in New Zealand and we look forward to continuing a positive working relationship with Forklift Hire Services.”
All over the world, in warehouses, factories, freight terminals and shipping yards and all other industrial sites, companies use forklifts to move, lift and stack loads.
According WITS (World Industrial Truck Statistics), 1,534,000 units were shipped in 2018 and the lift truck market has grown from 872,000 units in 2008 to 1,534,000 (estimated) units in 2018 at a CAGR of 5.4%.
However, this increased use comes with its challenges, in particular with regards to the safety aspect for forklift operators and those working in the vicinity.
RCT’s Industrial Senior Business Development Manager, Grahame Don talks about the importance of reducing the risks in forklift operations and the materials handling industry.
The safety and well-being of forklift operators around the world is of utmost importance. In developed economies like the US and Australia, the human and financial cost of forklift-related incidents for the employees, industry and community is substantial.
According to the US Bureau of Labour Statistics, forklifts caused 85 work-related deaths and 7,940 nonfatal injuries in 2018. Non-fatal injuries in 2018, were around 16% more than that in 2015.
However, there are precautions and initiatives companies can undertake to prevent these incidents from occurring.
Around the world, Government safety bodies require personnel to obtain a forklift licence before they are authorised to operate lift trucks due to the high-risk nature associated with working with heavy equipment. Today, companies are required to keep a record of employee’s licences, making note of when they need to be renewed. It is however not easy to keep up-to-date with current and expired licences when this information is recorded manually. The use of an industrial fleet management system, like RCT’s SmarTrack® Global, can prevent unauthorised use of forklifts with workers needing a pin code or swipe card to access a machine. SmarTrack® Global can also keep a record of valid licences ensuring everyone operating the machines are legally authorised to do so.
These include the simple task of a pre-operational forklift checklist. Ensure operators check the forklift is in safe, working order before you start. This checklist would typically comprise of checking the likes of tyres, fluids, seating, warning devices, seatbelt, controls and breaks. It is important a system be implemented that is both easy to manage and has longevity. Manual, paper checklists can often become quite tedious and people can become complacent about them. Due to these reasons, many companies are going digital by implementing fleet management solutions to address this safety compliance issue. Currently, SmarTrack® Global is one of the few fleet management systems with a multi-lingual checklist function to ensure operators can nominate their preferred language.
It might sound so simple, but wearing a seatbelt while operating a forklift is the most important safety precaution that operators can take. Seatbelts play a significant role in lessening the chance of serious injury and even death should a roll-over occur.
However, it is quite common for operators to overlook this simple task when operating a forklift for just a few minutes; for example, when they need to move a forklift a short distance to relocate it. These bad habits must be broken, and with a buckle monitoring system that alerts and reports when a seatbelt is not worn, can ensure compliance as they can reinforce safety policy and training at the site. These alert systems are a feature of fleet management systems like SmarTrack® Global.
It is one thing to put in place a speed limit for forklift operators, but it is another to enforce that people abide by it to ensure safety. It is not 100 per cent reliable as there is human error/disobedience. Being able to alert drivers to exceeding the speed limit helps to prevent accidents occurring that are caused from speeding, such as driving into trucks and other equipment, or even rollovers. Speed alerts can create behavioural changes and can be executed with fleet management solutions such as SmarTrack® Global.
A forklift maintenance program should be mandatory in any organisation operating these industrial trucks. Preventative maintenance and inspections should be performed according to the manufacture’s recommendations and relevant standards. This servicing schedule should also adhere to components added to the forklift. In addition, all servicing should be carried out by someone qualified or trained to do so. It is easy to let servicing slide or perhaps forget when it’s due entirely. The use of a service scheduler, via a fleet management solution ensures the person in charge receives a notification when a service is due, based on hours and the calendar year, is extremely beneficial to ensure this important task is not forgotten about and for companies to remain compliant. In addition to this, service personnel are alerted to any checklist maintenance issues promptly.
SmarTrack has the ability through it’s “Out Of Service” feature to enable units to be locked out in the event of an impact. The unit can only be re-activated by the appropriate Manager or Technician. To assist management with the identification of risks within the workplace, SmarTrack® Global includes an area for incident reports. This enables information to be stored electronically.
While the safety and well-being of employees are, the most important reason for ensuring all these rules are abided by at all times, compliance also weighs in heavily. Companies have a duty of care for their staff, especially those operating heavy machines such as forklifts. Digitising the process improves safety exponentially, and ultimately saves organisations money.
Smart technology specialist RCT has finalised a project that guarantees appropriate and supervised control of forklift operations within a prison on the east coast of Australia.
Industrial specialists at RCT in Brisbane worked with Toyota Material Handling Australia (TMHA) to customise a Toyota 8FG25 Forklift to meet stringent safety guidelines so the machine could be operated safely within a prison in the region.
RCT technicians subsequently designed a technology package consisting of a ControlMaster® remote shutdown solution installed on the forklift linked to a handheld transmitter.
The system is designed so that the site supervisor must use the handheld transmitter to engage the forklift after which trained and certified machine operators can use the forklift as normal.
The technology package is also designed to automatically shutdown the forklift if it is more than 200m away from the handheld transmitter or if any part of the solution is interfered with.
RCT Account Manager – Industrial Nicholas Noorman said the project will provide positive results for the client going forward.
“Our solution ensures all machine operators will use the forklift in an appropriate and safe manner in line with prison guidelines,” he said.
“We have received very positive feedback from prison authorities and from THMA and look forward to providing ongoing technical support in the future.”
“This technology package can quite easily be applied to other scenarios such as forklift driver training courses to better equip and supervise a workforce.”
The solution is another addition to RCT expansive industrial product range which includes fleet management systems, safety products and electrical spare parts.
Global automation specialists Schneider Electric and RCT partnered up in 2015 with the delivery of an fleet management solution for a number of forklifts in Singapore.
RCT’s SmarTrack® Industrial Fleet Management solution was chosen over competitors for a myriad of reasons including, the fact it was independent, user-friendly, and web-based.
“The first order of 35 units was supplied to Schneider Electric’s headquarters in Asia two years ago and the working relationship has grown from there,” said RCT’s Industrial Business Development Manager Grahame Don.
Just like RCT’s relationship with Schneider, the SmarTrack® Industrial Fleet Management solution has evolved and expanded over time.
Over the past two years RCT has supplied SmarTrack® for numerous forklift users nominated by Schneider in the Philippines, Indonesia, Malaysia and Vietnam. As distribution expanded, so did the need for the product to be adaptable to cater to different languages and as a result the product is now available with a multi-lingual display feature.
“RCT recognised that English wasn’t the first language for many operators and it was necessary to cater to the needs of the end-users,” said Mr Don.
“Therefore RCT’s product development team worked on multi-lingual options and as a result, the solution is now available in multiple languages.”
“Having this option available means the solution is adaptable worldwide.”
Together with Schneider Electric, RCT has been able to cater to clients direct needs; an attribute RCT endeavours to achieve with each project in undertakes.
