Flint Systems is Creating a Safer Forklift Operating Environment

This March 26, Halldale reported Michelin Sp. z o.o.’s procurement of a VR forklift training simulator from Flint Systems.

By coincidence, this April 18, OSHA.com’s blog provided the attention-getting statistic that “one in 6 workplace deaths involves a forklift.” The posting continued, “but it’s worse when you consider that 70% of forklift accidents are preventable with standard safety measures, according to the Occupational Safety and Health Administration (OSHA).” While OSHA’s statistics are US-focused, this review presents the imperative for companies in and beyond the nation to consider training as one strategy to educate and inform workers about forklift accidents. 

To continue the series of short articles on learning technologies being brought to bear in safety critical industry training enterprises, the author gained insights from Poland-based Flint Systems on the VR forklift training simulator part of its expanding S&T portfolio.   

Customer Overview

Maciej Kniter, marketing manager at Flint Systems, first noted that Michelin Sp. z o.o. (Michelin) employs around 5,000 people in Poland, with the majority working in the Olsztyn plants. Michelin operates on 187 hectares there, producing various types of tires. “It's hard to imagine this production without forklifts operated by skilled drivers,” he added.   

Michelin is paying particular attention to available solutions that streamline training processes, making training more attractive and effective while ensuring a much higher level of safety. 

One training tool in their corporate enterprise is the VR forklift training simulator, created by Flint Systems, a producer of VR training simulators for various vehicles and machinery.

Forklift in VR 

The forklift simulator is one of Flint Systems’ flagship products. The device was developed at the request of the nation’s Office of Technical Inspection in 2021 (delivered to it in 2022). 

The corporate marketing manager explained the simulator consists of two parts – software and hardware. The hardware includes VR goggles, a computer, a motion platform, a seat, safety belts, a steering wheel, pedals, a gearbox, and distributor levers, while the software is the training application. Kniter emphasized, “The application connects all the hardware components and places them in the virtual training world.” 

Kniter then explained the training itself involves taking a seat in the simulator, putting on the goggles, and immersing oneself in the virtual environment (such as a hall, warehouse, ramp, etc.). “Training can be conducted with an instructor's participation or independently using prepared exercises/tests. The instructor, sitting beside a computer, observes the training and gives instructions. They can change views, allowing them to see exactly what the trainee is doing from different positions.” 

Flint Systems also added rigor to the VR forklift training scenarios. The corporate marketing executive pointed out the simulator allows the instructor to change weather conditions, time of day, and initiate hazardous situations. “Moreover, with the scene editor function, the instructor can arrange the scenery and prepare various sets of exercises. This type of course offers numerous advantages. Among them are realistic training (immersion in the virtual world) on an accurately reproduced machine, learning in a safe environment with the possibility of training on life-threatening situations, and high efficiency (supported by PwC research). 

Special Project for Michelin 

Michelin ordered and received a forklift simulator in 2023. The global manufacturing entity had specific requirements in this VR-for-training use case: streamlining both training and verification/recruitment processes for new operators; and enhancing their safety. 

Here’s another important underpinning of this project. Flint Systems delivered a training device that meets the customer’s requirements to enhance workforce training and safety efficiencies, having also replicated a warehouse hall based on materials provided by the client, such as plans, 3-D models, and detailed inventories and local inspections. 

All this was done to replicate key elements of the work environment at Michelin. The marketing executive said the entire surroundings, including the interior of a 400m (1312ft)-long hall, had to be transferred to VR. “Flint Systems specialists also had to replicate a specific forklift model with all its characteristic features and physics. Loads and shelf arrangements had to reflect the actual state of the real hall so that trainees could learn the corridors and maneuvering within the hall during training and orient themselves by observing their surroundings,” he explained and continued, “In this way, the loads themselves were also replicated. They have a special lifting method based on holes that function similarly to rails.” 

Effect of the Forklift Simulator Implementation 

The demand for forklift simulator training is expanding in Poland. 

 Kitner reported Michelin is another large company in the nation that decided to purchase a forklift simulator. “In addition to large enterprises, higher education institutions and technical/vocational secondary schools are also interested in buying a VR forklift simulator.” the executive added. 

Grzegorz Szatkowski, Vice President of Flint Systems, added, “We are extremely proud that a large company like Michelin Sp. z o.o. has implemented our product to train and improve the skills of its employees. This collaboration confirms our ability to deliver high-quality training solutions created using VR technology, which meet the expectations of even the largest and most demanding market players. It is a great honor and confirmation of our product's value that Michelin recommends the Flint Systems simulator at safety conferences, for which we are very grateful.”