Warehouse forklift safety
A forklift and a person, on the same aisle
Amazon has been scaling its fulfillment network for over a decade. Hundreds of fulfillment facilities exceeding a million square feet each, with thousands of employees and vehicles on every site.
At that density, forklifts and people share the same floor around the clock. Industry-wide that runs to more than three incidents per hundred employees a year, and once injury, downtime and investigation are counted, each one costs upward of $200,000. Conventional proximity sensors only see line of sight — around a rack corner they see nothing at all.
Co-developed with the truck manufacturer, not bolted on afterwards
Redpoint partnered with one of the world’s leading material handling equipment manufacturers to co-develop a full RTLS warehouse platform — forklift collision avoidance and navigation, asset tracking and fleet management on one system.
At its core are Redpoint’s patented DL-TDoA and XDI technologies, which give every truck spatial awareness and let it react in real time to that facility’s own safety policy. Open APIs connect the system to telematics, WMS platforms and partner forklifts. Because the integration is native to the vehicle’s control unit, the safety response is closed-loop: the truck slows or stops itself, without waiting for an operator to react.
Ceilings too high, aisles too narrow, and no downtime
- Ultra-tall ceilings and dense shelving — geometry that defeats line-of-sight sensing
- Narrow-aisle environments — where a truck and a person cannot pass without one giving way
- Non-stop 24/7 operating cycles — no maintenance window to install into
Redpoint extended both the product and the deployment tooling to hold performance in the most complex warehouse configurations, and the integration is certified to IEC 61508 and ISO 13849-1 for functional safety.
From 40 sites to more than 80
The rollout has roughly doubled since May 2025. Redpoint now runs across more than 80 of Amazon’s large-scale fulfillment centers — around 60% of their largest US distribution and warehouse facilities — with new sites going live continuously and consistent, high-reliability performance across all of them.
- 98% of preventable forklift incidents avoided — and zero false alarms at safety-certified sites
- Closed-loop response in under 100 milliseconds — from detection to the truck slowing or stopping
- 99% of positions accurate to within one meter — sustained in live warehouse conditions
- 87% reduction in defects — and a 13% improvement in picking efficiency
- 14-month average payback — across deployed sites
Across the wider deployment the platform now covers more than 100 million square feet, 10,000+ forklifts and 40,000+ AGVs, certified to SIL2/PLd. Redpoint continues to work with Amazon on further RTLS-enabled use cases.
80+
Facilities live
98%
Collisions prevented
<100 ms
Closed-loop response
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60%
of Amazon’s largest US distribution and warehouse facilities run on Redpoint
Customer
Amazon