Due to 'I Cha,' 100 Annual Deaths in the US... Sales Plummet with Factory Automation

The Main Culprit of Factory Safety Accidents, Forklifts
Tesla and Whirlpool Replace Forklifts with Robots

As the wave of factory automation sweeps across the United States, there is a growing trend to gradually eliminate forklifts. With around 100 deaths each year caused by forklift-related safety accidents, automation has emerged as a solution to address this issue. Forklift manufacturers are responding by developing autonomous driving technologies.

The Wall Street Journal (WSJ) recently reported that U.S. manufacturers are moving to eliminate forklifts, which have been essential equipment for over 100 years, to enhance productivity and safety. In 2023, forklift retail sales dropped by 28% compared to the previous year, marking the largest annual decline in 14 years.

Mercedes-Benz has been working since 2018 to reduce the number of forklifts in its U.S. factories. Tesla, driven by CEO Elon Musk’s strong interest in process automation, has been reducing forklift numbers and exploring automated systems, actively deploying hand carts and tow-type unmanned transport robots called tuggers throughout its facilities. Electronics manufacturer Whirlpool also eliminated forklifts at its Ohio plant, using transport robots (tuggers) to deliver parts to employees on the assembly line.

Larry Perlman, founder of the factory safety consulting firm Safety & Consulting Association, said, "Until about 10 years ago, hardly anyone was looking for equipment to replace forklifts. Nowadays, about 10% are seeking alternatives, and as robots for material transport become more widespread, the replacement rate is expected to increase further."

Forklifts are vehicles used to safely lift and move heavy objects in logistics warehouses, factories, and construction sites, and are considered essential equipment because they enable smooth operations even in narrow spaces. However, various incidents and accidents caused by forklifts at industrial sites every year have become a serious problem. According to U.S. federal government data, nearly 100 people die and 7,500 workers are injured annually in forklift-related accidents in the United States.

In 2023, a series of fatal forklift accidents occurred in the U.S. within a short period, raising concerns. Accidents happened when forklifts carrying loads failed to see other employees standing ahead or when forklifts loaded on trucks fell, crushing employees to death. In addition, there have been lawsuits demanding compensation from forklift manufacturers for injuries caused by forklift accidents, and related incidents continue unabated.

Forklift manufacturers have strengthened safety devices and established regulations requiring mandatory training before operation. At the same time, fearing a decline in demand, they are developing forklift technologies that can operate autonomously. Brett Wood, North American president of forklift distributor Toyota Material Handling, predicted, "A major transformation in the forklift industry could occur within the next 5 to 10 years."