Most plants have speed signs, painted walkways and a forklift rule sheet. Far fewer have one traffic management plan that says where vehicles run, where people walk, where the two meet and how anyone knows the plan still works. Layouts change, temporary routes become permanent, and near misses go unreported because nobody thinks a close pass counts. AI vision can now count every vehicle-pedestrian interaction by zone, so the plan gets reviewed against what really happens on the floor. See those counts on a live floor plan in a short traffic demo.
Build the Traffic Plan Around Where Near Misses Really Happen
iFactory Traffic Analytics uses AI vision to count vehicle-pedestrian interactions, speeding events and crossings outside marked points. The counts roll up into a zone heat summary, so EHS can change layouts, crossings and training based on evidence instead of hunches.
Five Layers of Control, Strongest First
The UK HSE guide to workplace transport safety (HSG136) groups the risk under three headings: safe site, safe vehicle and safe driver. Inside the site heading, the order of controls matters. Removing a vehicle movement beats painting a line, and a barrier beats a rule that relies on memory. Build the plan from the top layer down and lean on rules and training only for the risk that is left. Talk through your own layers with our EHS team.
The Requirements Behind a Site Traffic Plan
In the US there is no single OSHA standard called traffic management. The duties sit in the forklift standard, the materials handling rules and the walking-working surfaces rules, with a consensus standard for the trucks themselves. Your mobile equipment rules should trace back to each of them. The UK keeps the guidance in one document, which makes it a useful structure anywhere. Map your current rules against these in a plan review.
Three Kinds of Route, Each With Its Own Rules
HSE puts it simply: roadways and footpaths should be separate whenever possible. Good traffic route design sorts every route into one of three kinds and gives each kind its own rules. Walkways should follow desire lines, the paths people really take, because a walkway that adds a detour will be ignored by the second week. Get help sorting your routes from our support team.
Doors are where routes cross without warning. Give people and vehicles separate doors where you can, and fit vision panels so each side can see what is coming.
Where People and Trucks Must Meet, Design the Meeting
A crossing is where separation stops, so it deserves the most design effort. HSE guidance asks for crossings that are marked and signposted, barriers or deterrent paving that guide people to them, and lights, bridges or subways where traffic is heavy. Wide roads may need an island refuge so people cross one lane at a time. Review your busiest crossing with our traffic engineers.
Speed Limits Are Set by the Site, Not by OSHA
OSHA gives no number. 1910.178(n)(1) says authorized plant speed limits must be observed, and (n)(8) says a truck must always run at a speed that lets it stop safely. That puts the limit in your hands, based on stopping distance, load, floor surface, visibility and how many people are around. HSE adds that speed humps should not be used where forklifts operate. The rules below are illustrations of the kind of limit a site might set. Ask our safety team how others set theirs.
A sign alone is a hope. Pair it with speed limiting on the trucks where available, signs repeated along long routes and a count of speeding events by zone.
Plan Reviews Built on Counts, Not Guesswork
iFactory Traffic Analytics counts vehicle-pedestrian interactions, speeding events and crossings by zone and shift. EHS sees which layout change or training topic the data supports, then checks whether it worked.
Four Weeks of Interactions by Zone
An interaction is a person and a moving vehicle inside the distance your site sets. Most are harmless on their own. The value is the pattern: a zone or shift where counts keep climbing usually points to a layout problem, not a careless worker. Interactions are counted whether or not anyone files a report. The figures below are illustrative. See how the map is built in a live walkthrough.
From Camera Frame to Plan Review
Traffic Analytics does not replace walkways, barriers or training. It measures whether they work. Video is processed on site, people are detected as people rather than identified, and only counts and short clips for review leave the edge server. Each camera view is split into the same zones your plan uses. Ask our support team how zones are drawn.
Three Changes the Data Could Point To
These are illustrations of how counts turn into plan changes. They are not case studies, and every change should still go through your own risk assessment. Walk through your own zones in a scenario session.
A Plan on File vs a Plan That Gets Tested
Most traffic plans are accurate on the day they are drawn. The difference between a plan that ages and one that improves is a regular, evidence-based review with a named owner. Set up your review cycle with our EHS specialists.
- Drawn once when the layout was set
- Reviewed after an incident
- Near misses depend on someone reporting
- Rules enforced by occasional spot checks
- Reviewed monthly with zone counts
- Every layout change gets a before-and-after check
- Interactions counted whether or not anyone reports
- Training aimed at the zones and shifts with rising counts
One Sheet per Traffic Zone
Fill in one sheet for each zone on your site plan. Together the sheets form the written plan, and each one tells the camera system which rules to count against. Get a blank version from our team.
Cameras, Traffic Models and Edge Server, Delivered as One
iFactory delivers Traffic Analytics as a turnkey bundle. A pre-configured NVIDIA AI server ships racked and ready with vehicle, person and crossing models pre-loaded, so video is processed inside your plant. You rack it, plug in power and Ethernet, and the AI is live. To scope it for your site, talk to our deployment team.
- Pre-configured NVIDIA AI edge server, racked and ready
- Cameras for docks, cross-aisles and yard lanes, or links to suitable existing ones
- Models for vehicles, people and crossing behavior
- Zones and crossings drawn from your site plan
- Heat summaries by zone, shift and week
- Cabling, network setup and EHS team training
- 24×7 remote monitoring of models and hardware
Zones and crossings agreed from your plan, cameras and server installed, network connected.
Models tuned to your trucks and layout, then four weeks of counts collected before any change.
Heat summaries go live, the first plan review runs and the first layout change is tested.
Traffic Analytics Built for Plan Reviews
iFactory turns camera views into the numbers a traffic plan review needs, zone by zone and shift by shift. See it on a sample site in a short session.
Plant Traffic Management Plan Questions for Plant Managers
Put Numbers Behind Your Next Plan Review
Count interactions, speeding events and crossings in the zones that matter, then test every layout change against real data. The full system is delivered turnkey and goes live in 6 to 12 weeks.
