Automotive plants prevent forklift-pedestrian collisions by planning traffic as tightly as production. Common measures are separated and barriered walkways along assembly lines, defined forklift routes and one-way loops, controlled crossings with gates or lights, low speed limits near line-side delivery points, and replacing forklifts with tuggers or automated vehicles where material flow is predictable. Many plants add active detection on top: tags or cameras that warn drivers and workers and, on compatible trucks, reduce speed in pedestrian zones. Location data on material flow helps place these controls where traffic actually concentrates.
The full guide is Forklift safety in manufacturing plants, which covers the hazard patterns that differ from warehouses. In a plant, the people at risk include line workers, maintenance crews and visitors who do not think of themselves as working near forklifts, so walkway discipline and crossing design carry more weight than training alone.
OSHA 1910.176(a) requires aisles to be kept clear and permanent aisles to be marked. Start from the hierarchy of controls: remove forklift traffic from line-side work where tuggers can do the job, separate what remains, then add detection at the crossings and zones that stay shared.