Tips for developing a traffic plan: theory and practice

A traffic plan identifies all the traffic flows and intersections that pedestrians, trucks, forklifts, and other vehicles follow in your organization. It provides an overview of traffic rules, circulation, bottlenecks, and hazardous situations across your site. It briefs employees and visitors, highlights key points of interest, and provides guidelines on safe conduct.

A traffic plan is essential because it helps create a safe working environment for various users. Pedestrians, internal transport vehicles, and trucks all share the same space, creating major safety risks. A traffic plan shows you how to optimize these traffic flows and enhance safety. 

Developing a traffic plan is not a quick process. The first question to ask is: should I create the traffic plan alone or seek expert assistance? Even if you are familiar with your business environment, you might overlook some high-risk situations. In other words, seeking help is a good idea.

An effective traffic plan balances various aspects:

• Bottlenecks

Where do problems occur or potentially occur?

•  Traffic flows

What modes of transportation move around your site and what routes do they take? 

• Regulations and internal traffic rules

What are the traffic rules on-site? What are the rules for organizing goods within the company? Learn how to organize your warehouse more effectively.

• Accident prevention and worker protection measures

This involves substantial work, including drafting a clear evacuation plan and setting out floor plans with risk zones. Additionally, you will need to install the necessary signage and physical protection measures on-site. For instance, it is crucial to safely separate road users. Each user – pedestrians, forklifts, trucks – needs its own designated space. Clearly define how drivers and pedestrians should use the space and implement this through physical protection measures, such as safety barriers, bollards, handrails, safety gates, etc.

When developing a traffic plan, it is useful to work in phases.

• Inventory

The first phase involves mapping all traffic flows. You will also list existing resources, current traffic regulations, and signage.

During this phase, you talk to the safety manager, as well as the warehouse and production managers, forklift or pallet truck drivers, and other employees. They face these risks daily, so their input is crucial. Their involvement also makes them feel engaged, ensuring they will follow the rules and act as ambassadors.

• Identifying solutions

In the second phase, you will seek potential preventive solutions and protection products. These solutions should channel hazardous traffic flows and enforce new traffic rules. For example, you can implement various physical protection measures. Examine everything in detail with the goal of making the workplace safer. 

• Establishing rules

In the third phase, you make arrangements to implement the traffic plan. Clear instructions in the form of rules and agreements enable you to execute the plan. The solutions are clearly communicated to ensure everyone is informed and there is no confusion. Decide which colors will be used for signage in the work environment as well as the rules, lines, and signs that should take priority.

• Agreements and guidelines

Implementation is the fourth and final phase. You need to rely on the commitment and cooperation of your internal staff and external parties.

To implement a traffic plan, the first step is to install signage. This can be easily done using floor marking tapes. Floor marking tape can be used to indicate clear walking or driving zones, as well as the direction of travel and traffic routes for pedestrians and forklift operators. The markings also indicate the required distance between pedestrians and forklifts.

They can also designate different zones. Determine which areas can be designated for work, storage, or parking. This prevents lanes or pedestrian areas from being used for unloading goods. 

To create a clear structure and understanding of the markings, use the following color definitions:
 

• Red: Prohibited area
• White: Storage area
• Yellow: Lanes and parking
• Green: Free zone
• Blue: Pedestrian zone

In addition to floor marking tape, you can use other signage methods. For instance, pictograms are good at attracting attention. We recommend following the ISO 3864 color scheme when applying safety markings and signs.

• Yellow with black letters: Caution and instructions to avoid damage/injury, warning
• Blue with white letters: Designation or obligation and protection
• Green with white letters: Help indicator, information
• Red framed sign with prohibited pictogram
• Red area with white letters: Emergency prevention

However, other colors can be used, such as orange safety markings for chemical storage. Gray and black line markers can be used to change lines that no longer match the current color scheme.