Kelvin TOP‑SET® Investigation Eliminates Vehicle–Pedestrian Near Misses
Independent investigation revealed layout, communication and supervision gaps — and replaced them with engineered separation, visual controls and disciplined radio language.
Overview
A national logistics operator faced recurring HiPo near misses at a cross‑dock site. We led an investigation using Kelvin TOP‑SET® to uncover causes and implement verifiable fixes.
Key Actions
- Fixed barriers + one‑way vehicle flow; removed conflict points.
- LED “bay live” beacons + high‑contrast floor stencils; mirrors at blind corners.
- Standardised hand signals + three radio call‑outs (“approach”, “in bay”, “clear”).
- Mandatory pause on adjacent bay moves while marshaling; simple checklist.
- Yard‑specific sign‑off + quarterly micro‑drills; lighting levels increased.
Results
- Zero recurrences at 12‑week follow‑up; stable pedestrian–vehicle separation.
- Consistent radio discipline observed in weekly leadership rounds.
Transferable Lesson: Don’t sign crossings — remove them. Make SOP triggers binary and verifiable in the field.