Orbiterra

What it does

This system assists forklift operators in tight warehouse environments by offering visual guidance, auto-alignment support, and intelligent route suggestions. It addresses key pain points like poor visibility, low efficiency, and idle equipment.

Your inspiration

This idea emerged after observing forklift workers struggling with tight warehouse layouts, repeating loading attempts, and working with outdated task sheets. Even experienced operators often failed to align cargo efficiently. Through interviews with logistics station managers and forklift company employees, a pattern of stress, wasted time, and idle machines became clear. The concept was shaped by these frustrations, aiming to create a solution that offers clarity, efficiency, and real-time support in the most demanding warehouse conditions.

How it works

The system combines a small onboard display with real-time sensors and warehouse mapping. As a driver begins a task, the screen shows a simple, visual route to the cargo. Ultrasonic sensors and visual cameras help align the forks automatically by detecting the exact position and height of the pallet. If a task involves complex turns or blocked paths, the system suggests alternative routes. Idle forklifts are managed through a centralized scheduler, ensuring balanced workloads. The design avoids jargon-heavy tech; instead, operators receive easy-to-follow cues like arrows, color-coded zones, and a guided step-by-step interface that responds to movement and cargo progress in real time.

Design process

The project began with field interviews at three logistics sites and observational research of forklift operations. Initial findings revealed patterns of delay, misalignment, and user stress. A journey map and emotion curve were built to visualize the operator experience. From this, a behavior flow map was created, including loops and conditional branches, reflecting the real decision-making process. Prototypes began as sketches and low-fidelity interfaces focused on route guidance and fork alignment. We then integrated simulated forklift movements and manual input triggers in a desktop demo to mimic loading and unloading cycles. Feedback loops helped refine visual clarity and step timing. Key challenges included minimizing distractions while maximizing precision. The latest prototype includes a screen mockup with smart prompts and basic logic that adapts to route congestion and task priority. Each iteration improved usability based on direct testing scenarios and feedback from experienced forklift operators.

How it is different

Unlike traditional forklift systems that rely on driver expertise alone, this design embeds intelligence directly into the workflow. It not only visualizes tasks but adapts to real-time warehouse dynamics. Existing systems might offer cameras or GPS, but they don’t provide decision-making support. This design integrates route suggestions, fork alignment guidance, and idle forklift scheduling—all in a simple, operator-friendly format. Its behavioral logic is built from real-world pain points and includes branching, looping, and fallback options that reflect actual operator behavior. It’s not just a tool—it’s an intelligent companion that reduces stress, speeds up work, and minimizes errors without requiring deep technical knowledge or training.

Future plans

Next, we plan to build a functional prototype for live testing in real warehouse settings. Future versions will explore AR overlays for fork alignment, voice-assisted navigation, and cross-device scheduling. We aim to integrate with warehouse management systems (WMS) and scale for multi-vehicle coordination. Long term, the goal is to become a standard forklift interface module adaptable to different forklift brands and warehouse layouts.

Awards