In intense materials handling environments—where precision, adaptability, and durability are non-negotiable—supporting lift truck operating best practices requires a comprehensive, multi-faced approach. This includes training, real-time support and monitoring, and evaluation. Technology is making a welcome impact to advance all of these areas, and it’s an expanding area. For example, the global forklift pedestrian warning system market alone had a value of $200 million (US) in 2024 and is predicted to grow.
Inexperienced operators and short-staffed workforces exacerbate the challenges that industrial handling businesses face. Yet forklifts remain essential in keeping operations moving and hitting targets on time and on budget. From fast-paced manufacturing facilities to intense timber and construction sites, a comprehensive forklift technology strategy can help bridge the productivity gap while working to support performance and operational resilience
Forklift telematics monitor and manage operator performance
Modern forklift telemetry systems can track several aspects of fleets, from equipment diagnostics and utilisation to individual operator performance. All this information can be accessed in real-time via desktops, laptops, and mobile devices to facilitate informed fleet management decisions and assist with managing operator behaviour.
Tracking forklift truck information by the specific operator provides visibility to information like travel locations and idle time. Some systems can even notify managers when impacts happen, with information about where the incident occurred and who was operating the forklift truck. This forklift fleet management data can be used to help identify high performers who deserve recognition and those who may require more training.
These functions are all accessible via the Wireless Monitoring tier of Hyster Tracker™ which is now included as a standard feature on Hyster® electric and internal combustion engine (ICE) counterbalanced lift trucks. The wireless monitoring solution enables operations to schedule and track preventative maintenance while gaining a better insight into their total cost of operations.
Certain systems can also be used to apply equipment performance limitations based on operator experience and skill level. For example, new recruits might have their trucks capped at slower speeds to help reduce potential risk, while more experienced operators can have controls set to allow access to higher levels of equipment performance.
Forklift telematics options may also restrict equipment access to only operators with the proper certification for that truck type, preventing operators without certification from even starting equipment. Notifications can also be sent for operators with certifications to expire soon, so they can go through proper processes to get re-certified and maintain productivity. Hyster Tracker includes Wireless Access and Wireless Verification levels to support these differing levels of functionality.
Real-time support for forklift operators
While lift truck telemetry can help facilities monitor and reactively address operator behaviour and truck impact events at their facility, operator assist systems with integrated stability control offer a more proactive approach to help minimise certain tip over risks and automatically reinforce safe operating practices. The optional Hyster Dynamic Stability System is one such solution, promoting lift truck stability by applying limitations to truck performance in certain conditions, accompanied by audible and visual alerts that communicate the cause of the intervention to the operator. These automatic interventions happen in real time, helping to support stable travel and provide operators with an immediate layer of feedback that can help reinforce the proper lift truck operation established during their training.
In addition to stability systems, certain applications can take advantage of a different type of forklift operator assistance technology that limits truck performance based on real-time information about not only the equipment, but also the operating environment. Businesses can use these advanced operator assist systems, like Hyster Reaction, to proactively adjust truck performance when pedestrians and other lift trucks are detected in proximity, when objects are detected in the path of travel, or in response to facility-specific rules, such as excluding equipment from entering designated areas like pedestrian zones.
Unlocking potential in demanding environments
No two facilities are alike. Managers must choose the right forklift technologies to fit their operation, employees, and equipment. This is the key for taking technologies from simple enhancements to powerful enablers that allow operations to maintain high standards and meet demands. All the while developing a materials handling workforce that is empowered by forklift technology, not replaced by it.
Discover forklift fleet management systems that support productive and agile operations, today and tomorrow. Talk to your local Hyster® dealer for more details on forklift monitoring systems and operator assistance solutions.