This master’s thesis was conducted at Linköping University in collaboration with Toyota Material Handling Europe (TMHE), at their Research and Innovation (R&I) department, with the aim of developing innovative design solutions to improve safety for operators using motorized stackers and pallet trucks. The primary aim of this thesis was to gain a deeper understanding of the most common injuries affecting forklift operators, as well as how these injuries occur. The aim was achieved by addressing the following research questions: What are the most common injuries and injury risks for forklift operators? and What design solutions for safety systems on motorized stackers and pallet trucks can reduce the risk of accidents and/or mitigate the consequences in the event of a potential accident?.

The study found that foot injuries are the most common, followed by injuries to the hands, legs, shoulders, back, and head. Repetitive strain injuries in the neck, shoulders and back are also prevalent, primarily due to monotonous tasks and static postures. Frequent accident types include collisions, falling loads, falls from heights and crush injuries. These incidents are often caused by insufficient maintenance, inadequate training, loss of control, or slip and trip incidents. Moreover, the underreporting of minor incidents results in missed warning signs, which hinders preventive action and increases the risk of more severe accidents.

The thesis also presents design solutions for motorized stackers and pallet trucks, emphasizing that safety solutions must be complemented by operator training, behavioral awareness, and a strong safety culture. The phenomenon of risk compensation further underscores the need for ongoing engagement and consistent safety practices. Furthermore, the study highlights that safety and productivity are not mutually exclusive; rather, a well-implemented safety framework contributes positively to long-term efficiency and profitability.

As a practical outcome, the project resulted in the development of a collision warning system utilizing haptic technology to improve the safety of forklift operators. The system alerts operators through vibrations in the tiller arm with handle and foldable platform, making it effective in noisy and visually distracting environments. Haptic feedback helps reduce cognitive load, improves spatial awareness, and acts as a nudge toward safer behaviour. Various vibration frequencies, amplitudes and pulse patterns signalling different levels of urgency were tested in the user test. In the design of the vibrations, ergonomic factors, glove use, and user differences were considered. This is an aspect that should be considered in any potential future implementation. It is also important to acknowledge that forklift and material handling operations vary significantly, requiring the vibrations to be tailored to the specific needs of each operation. The technology is novel in the forklift industry and shows strong potential for broader applications across other forklifts and use cases.