Terex Utilities Cuts Forklift Speed Violations by 95% with AI-Powered Safety Monitoring

Client Profile

Industry: Manufacturing — Aerial Work Platforms & Utility Equipment Parent Company: Terex Corporation (10,000+ employees worldwide) Facility: Manufacturing plant with 20+ monitored zones spanning assembly lines, production corridors, docking areas, and equipment staging Baseline Period: December 2025 – January 2026 (six weeks)

Terex Utilities is a division of Terex Corporation, a global manufacturer of lifting and material processing products serving infrastructure, utility, and industrial customers. Their manufacturing facilities operate complex environments with heavy machinery, forklifts, elevated work areas, and large workforces — creating a high-stakes safety landscape that demands constant vigilance.

The Challenge

Like many manufacturers, Terex Utilities faced the challenge of maintaining consistent safety compliance across a large, dynamic plant floor. Periodic safety walks and manual audits left significant coverage gaps, and there was no scalable mechanism to monitor PPE compliance or vehicle-pedestrian interactions continuously.

Specific challenges included:

• No continuous visibility into PPE compliance across all work zones
• Vehicle-pedestrian pathway conflicts creating near-miss risk in high-traffic production corridors
• Forklift speed violations occurring in areas without consistent enforcement mechanisms
• Restricted area breaches going undetected between manual safety audits
• No quantitative safety baseline to measure the impact of improvement initiatives
• Safety personnel stretched thin — unable to maintain continuous presence across 20+ zones

The safety team needed data — real, continuous, and actionable — to drive meaningful behavioral and operational change.

"We needed a system that could watch every corner of our facility simultaneously and give us the data to act before a near-miss became an injury. Visionify gave us the visibility we didn't have — and the evidence to back up every change we made." — Safety Leadership, Terex Utilities

The Solution

Visionify integrated its AI-powered computer vision analytics platform with Terex Utilities' existing camera infrastructure across 20 monitored zones. The platform runs purpose-built deep learning models to detect safety events in real time, generate priority-tiered alerts, and log every incident with timestamped video evidence.

Five core safety scenarios were deployed:

• Area Controls (Pathways & Zones): Monitoring vehicle-pedestrian pathway conflicts, restricted area breaches, and zone compliance across production corridors and docking areas
• Worker Health & Safety (PPE): Real-time detection of six PPE categories — helmets, gloves, hi-vis vests, goggles, face shields, and safety footwear — with granular violation tracking by type, zone, and severity
• Vehicle Controls: Continuous forklift speed monitoring and traffic flow analysis across all vehicle-active zones
• Housekeeping: Detection of unattended objects and obstructions that create trip or collision hazards
• Behavioral Safety: Identification of unsafe behaviors and practices that precede incidents

All monitoring runs on edge hardware deployed on-premise, keeping sensitive facility data within Terex's own network while enabling sub-second response times. Unlike traditional video monitoring that relies on humans watching live feeds, Visionify's AI watches every zone simultaneously, 24 hours a day, without fatigue or attention drift.

What the Platform Revealed

During the initial six-week baseline period (December 2025 – January 2026), Visionify detected 4,658 safety events across live production operations — establishing, for the first time, a quantitative picture of the risk landscape across the facility.

Safety Events by Category

Safety Scenario	Events Detected	% of Total
Area Controls (Pathways & Zones)	2,820	60.5%
Worker Health & Safety (PPE)	1,546	33.2%
Vehicle Controls	181	3.9%
Housekeeping (Unattended Objects)	72	1.5%
Behavioral Safety	39	0.8%
Total	4,658	100%

PPE Compliance Breakdown

Visionify detected 1,546 PPE-related violations across six equipment categories, giving safety managers granular visibility into compliance gaps that had previously gone untracked:

PPE Violation Type	Count	Severity
No Helmet	488	Low
No Gloves	406	Moderate
No Vest (Hi-Vis)	313	Moderate
No Goggles / Eye Protection	243	High
No Face Shield	89	High
No Boots / Footwear	3	Low

332 events flagged as high severity involved missing eye protection — among the most preventable and costly workplace injuries. This data fueled a targeted PPE coaching program directed at the specific areas and roles where violations were most frequent.

Vehicle & Area Safety

Vehicle and area controls represented the largest category with 3,001 combined events:

Event Type	Count	Risk Category
Vehicle in Pedestrian Pathway	2,503	Collision Risk
Pedestrian in Vehicle Pathway	198	Collision Risk
Forklift Speed Limit Exceeded	175	Speed Violation
Restricted Area Breach	117	Unauthorized Access
Person Near-Miss	6	Critical

Six near-miss events were captured — situations where a person came dangerously close to a vehicle or hazardous equipment. Each near-miss that goes unaddressed is a precursor to a recordable injury. Visionify's video evidence enabled Terex safety managers to investigate each incident, identify root causes, and take targeted corrective action.

Severity Distribution

Visionify automatically triages every event by severity, enabling the safety team to prioritize response:

• 3,600 Low Severity (77.3%) — coaching opportunities
• 718 Moderate Severity (15.4%) — escalated follow-up
• 340 High Severity (7.3%) — immediate attention required

High-severity events were concentrated in two categories: missing eye protection and vehicle near-misses with personnel — precisely the incident types that carry the highest risk of serious or fatal injury.

Measurable Outcomes

The baseline data didn't sit in a dashboard — it drove immediate action. Armed with clear, video-backed evidence of where safety risks were concentrated, Terex Utilities launched a structured internal safety campaign targeting the highest-impact issues.

95% Reduction in Forklift Speed Violations

Forklift speed violations were among the most actionable findings, with 175 recorded events during the baseline. Rather than relying on signage alone, Terex Utilities used Visionify data to launch a direct engagement program with forklift operators — sharing AI-captured video evidence during individual coaching sessions and team safety briefings.

The impact was dramatic: forklift speed violations dropped by 95%. Drivers could see exactly what the system was detecting, making coaching conversations concrete rather than abstract.

Infrastructure Changes Backed by Data

Beyond behavioral coaching, vehicle pathway data revealed structural traffic flow issues requiring physical intervention. Visionify's event heatmaps showed persistent pedestrian-vehicle conflicts in specific production corridors, giving leadership a defensible, data-backed rationale for facility changes:

• One-way forklift lanes established in primary production corridors to eliminate head-on vehicle conflicts
• Designated no-forklift zones created in high-pedestrian areas to physically separate vehicle and foot traffic
• Changes driven by AI-generated evidence, not anecdotal reports — creating multiple, overlapping layers of protection

Platform Accuracy & Continuous Improvement

Visionify's hybrid AI + Human-in-the-Loop review model continuously validates detection quality:

• 87.7% of all detected events reviewed by Visionify's dedicated safety review team
• 282 events received direct annotations from Terex Utilities' own safety staff
• 74.1% of customer-reviewed events confirmed accurate, with the remainder providing valuable operational context (task-specific PPE exemptions) that feeds directly into model calibration

As the platform learns the specific workflows, PPE policies, and traffic patterns of the Terex facility, detection accuracy continues to increase with every passing week.

What's Next

Visionify continues to operate at the Terex Utilities facility, now serving a dual function: verifying that safety improvements are holding, and continuing to surface new opportunities for intervention as conditions evolve. The platform provides ongoing value through continuous PPE monitoring, vehicle pathway verification, near-miss detection, timestamped video evidence for OSHA and audit readiness, and trend reporting that tracks safety KPIs over time.

Terex Utilities' results demonstrate what a successful AI safety partnership looks like: a platform that delivers immediate value through visibility, and lasting value through the behavioral and operational change it enables.