Leveraging Immersive Technologies for Safety Evaluation in Forklift Operations

This article presents a novel methodology for evaluating the safety of forklift operations in intralogistics systems using a multi-user simulation model integrated with virtual reality (MUSM-VR). Set against the backdrop of persistent safety challenges in warehouse environments, particularly for inexperienced operators, the study addresses the need for proactive safety assessment tools. The authors develop a simulation framework within the FlexSim 24.2 environment, enhanced by proprietary VR and server integration libraries, enabling interactive, immersive testing of warehouse layouts and operational scenarios. Through literature review and analysis of risk factors, the methodology incorporates human, infrastructural, organizational, and technical dimensions of forklift safety. A case study involving inexperienced participants demonstrates the model’s capability to identify high-risk areas, assess operator behavior, and evaluate the impact of visibility and speed parameters on collision risk. Results highlight the effectiveness of MUSM-VR in pinpointing hazardous intersections and inform design recommendations such as optimal speed limits and layout modifications. The study concludes that MUSM-VR not only facilitates early-stage safety analysis but also supports ergonomic design, operator training, and iterative testing of preventive measures, aligning with Industry 4.0 and 5.0 paradigms. The integration of immersive simulation into design and safety workflows marks a significant advancement in intralogistics system development.