Dispelling common myths about OAS in warehouse operations
Published: 10 March, 2025
As warehouses face growing demands for faster order fulfilment, many are turning to digital solutions like Operator Assist Systems (OAS) to improve productivity and safety. Robert O’Donoghue from Yale Lift Truck Technologies addresses and dispels common myths surrounding OAS to help operations make informed decisions
Today’s warehouses face constant pressure to fulfil greater volumes of orders at an increasingly fast pace, which depends on lift truck operators performing at their best, every day. To support this, some operations are choosing to digitalise more parts of their warehouse, including elements of their materials handling equipment operations and fleets. Turning to technology solutions such as operator assist systems (OAS) to help maximise productivity, maintain lift truck best practices, and support safe operations. However, as a relatively new technology, OAS are often misunderstood.
Lift truck operator assist systems (OAS) can offer alerts and automated assistance to support operators in real time on the warehouse floor. They can be used to consider equipment status or load stability, providing visual alerts or even performance intervention. Plus, more advanced OAS solutions can leverage information related to the operating environment, including precise, real-time location and proximity data to enable automatic performance adjustments for a range of scenarios tailored to warehouse operations. Below, we address and dispel some of the most common myths.
MYTH - OAS is just another name for telemetry systems already on the market.
The truth is that OAS is an umbrella term, encompassing various products and technologies designed to assist operators. It includes telemetry, and things like pedestrian awareness lights and alarms, automatic slow-down, lift lockout, and so much more to help operators adhere to best practices that support safety and efficiency in a digital age warehouse.
Telemetry is a technology solution that captures and reports lift truck status and usage, providing the data to inform a more reactive approach to managing operator behaviour. Other OAS features, however, can take a more active role, providing operators with real-time alerts and automatic performance limitations based on the real-world operating environment, load and equipment status, making it easier to adhere to best practices.
MYTH - OAS can risk reduced productivity and decreased throughput.
In particular applications, the right OAS is capable of both supporting site-specific initiatives and maintaining productivity, rather than prioritising one at the expense of the other. In fact, fast-paced e-commerce warehouses are well-represented among the early adopters of OAS.
Both productivity and lift truck operating best practices can be prioritised. The in-aisle muting feature on the Yale Reliant OAS, for example, allows two trucks to work in the same aisle without slowing each other down, though they are in close proximity. The narrow nature of tight warehouse aisles means equipment cannot keep the same distance, but they are not subject to performance reduction. However, different OAS offer different functionality and benefits. It is therefore important to select the right fit to support productivity in a specific warehouse.
MYTH - OAS is typically limited to ultrasonic technology for object and pedestrian detection, so it cannot register all potential hazards in the environment.
Many companies and OEMs use different technologies to detect objects, pedestrians or both. Technologies such as LiDAR, ultrawideband (UWB) and ultrasonic are all popular for these applications. Look for a system that can use either single or multiple means of detection, depending on the goals and needs of your specific warehouse application.
Some OAS offerings may be limited to one type of detection technology. If it can be configured with multiple detection technologies, the OAS will offer a greater level of awareness tailored to the unique needs of each location.
MYTH - Object and pedestrian detection only work in the path of travel, and if the object or pedestrian is standing straight up or vertically.
While vision technologies like LiDAR and ultrasonic sensing can detect obstacles in the direction of their orientation, some OAS can be configured with multiple sensors to enable detection in the appropriate direction depending on truck and obstacle location.
But what about unseen obstacles, such as a truck hidden in racking? Yale Reliant is an example of a technology where line of sight support uses UWB technology to account for and react to objects equipped with a powered badge within a certain radius. You don’t want to miss a pedestrian about to step out of the end of an aisle as a truck approaches.
Furthermore, OAS may be able to slow lift truck speed to a crawl based on location-specific rules, to discourage operators from entering certain areas, such as designated pedestrian zones, aisles, doorways and tunnels
MYTH - OAS reduces truck performance only to avoid obstacles.
It’s common for an OAS to enable features that help operators avoid hitting obstacles, such as reducing speed if an obstruction is detected or in response to location-based rules at intersections or high traffic areas. But with operators traveling quickly around corners carrying a risk of tip over, what about a feature designed to help operators maintain the stability of the lift truck and load?
You can look for an OAS that offers lateral stability when cornering. Travel speed can be decelerated based on the combined centre of gravity, of both the truck and load.
MYTH - An OAS can expand load capacity.
OAS does not enable extra load capacity. Instead, these systems provide a digital solution which may help lift truck operators avoid lifting loads that exceed the lift truck’s capacity limit. Load weight awareness is a type of feature available within some OAS which automatically stops lifting if load weight exceeds the truck’s threshold. Rather than just providing an audible or visual alert, to tell operators they are lifting a load that is too heavy – it simply prevents them from doing so.
MYTH - OAS only applies performance controls based on other trucks, objects and pedestrians that are connected to the same technology.
While an OAS can use a network of ultra-wideband tags to sense equipment, personnel and infrastructure, a technology like LiDAR can offer an extra layer of detection to sense obstacles in the path of travel even if they are not connected to the same network of tags.
Some systems may leverage both LiDAR and ultra-wideband tags for detection. As well as a real-time location sensing option, using the same network of ultra-wideband proximity tags together with beacons set up throughout the facility could help enable location-based rules like equipment exclusion zones and end-of-aisle slowdown.
Digitalising lift truck training
In addition to OAS, it’s important to build and support safe, effective habits through the correct training. In the UK, lift truck operator training should meet Health and Safety Executive (HSE) requirements and other local legislation and guidelines. However, much like OAS has brought technology to the warehouse, digitalisation has elevated lift truck operator training. From virtual reality simulators to modernised training videos and eLearning, there are new digital options and learning technologies that can support engagement and comprehension for warehouse workers and equipment operators.
Find what works for you
Businesses today are challenged to cope with a revolving door of employees, and must prioritise training, as well as constantly reinforcing operating best practices. Investing in OAS technology can help bring warehouses into the digital age and get the most out of mission-critical labour resources to keep pace with demand. OAS technology can help warehouses boost efficiency and adherence to lift truck operating best practices. But as with any new technology, the solution must suit the specific operation.
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