Safety Innovation Summary:
To improve pedestrian and equipment safety around automated T-Carts, the facility team added four additional photo eyes—one at each corner of the T-Cart—to supplement the two original floor-level sensors. These new sensors now scan three planes: the floor and two vertical levels on each side. This enhancement allows the T-Cart to detect potential obstacles, such as forklift forks, overhanging units on conveyors, or pedestrians entering the aisle before stepping in.

 

Implementation and Impact:
The upgrade was driven by incidents where conveyor overhangs made contact with the T-Cart during automatic operation. After overcoming mounting and programming challenges, the new sensor layout significantly improved detection accuracy and operational safety. The system now runs more reliably in automatic mode, reducing the need for operator intervention and maintenance while improving protection for both personnel and equipment.