SafeLog · Project

Safe Human-Robot Teamwork in Warehouses Without Separating Workers from Machines

manufacturingPilotedTRL 6

Imagine a giant warehouse where robots and human workers share the same aisles — right now, that's either dangerous or impossible because you have to fence off the robots completely. SafeLog built a system where workers wear a smart safety vest that robots can detect, so both sides can work in the same space without accidents. They also created AR glasses that show workers what to pick and where to go, plus smart planning software that coordinates robot fleets and human teams on the fly. Think of it like giving the whole warehouse a traffic control system where everyone — human or machine — knows where everyone else is.

By the numbers

16%

European e-commerce market growth in 2014

consortium partners

countries in consortium (CZ, DE, HR)

demo deliverables produced

total project deliverables

industrial partners in consortium

The business problem

What needed solving

Warehouses today must choose between full automation (expensive, inflexible) or manual labor — mixing the two is a safety nightmare because robots and humans cannot safely share the same space. This forces operators to dedicate separate zones, wasting floor space and limiting throughput. As e-commerce grew more than 16% in a single year, the pressure on warehouse capacity makes this separation increasingly costly.

The solution

What was built

SafeLog built a wearable safety vest that makes workers detectable to robots, an AR-based interface system (prototype and final versions) that shows workers task and environment information, a human intention recognition system using gesture control and path prediction, and a large-scale fleet manager with human-aware planning algorithms that coordinates mixed human-robot teams in real time. The project delivered 7 working demonstrators and 24 total deliverables over its 5-year run.

Audience

Who needs this

Large e-commerce fulfillment center operators (Amazon-scale or regional 3PLs)Warehouse robotics companies like Locus Robotics, 6 River Systems, or MagazinoAutomotive and electronics manufacturers adding cobots to assembly linesLogistics integrators designing new distribution centersWorkplace safety technology vendors looking for certified human-robot safety solutions

Business applications

Who can put this to work

E-commerce fulfillment and logistics

enterprise

Target: Warehouse operators and 3PL providers running large distribution centers

If you are a logistics company struggling to scale warehouse throughput without building entirely new facilities — this project developed a safety vest system and fleet management software that lets robots and human workers operate in the same aisles simultaneously. Current automation requires strict separation zones that waste up to half your floor space. SafeLog's approach removes those barriers, letting you add robots incrementally alongside your existing workforce. The e-commerce sector grew more than 16% in 2014 alone, and that pressure on warehouse capacity has only intensified.

Warehouse robotics and automation

mid-size

Target: Companies developing or integrating autonomous mobile robots (AMRs) for warehouses

If you are a robotics integrator whose customers keep asking how your robots can work alongside people — this project built a certified safety concept with a wearable vest and human intention recognition system that detects gestures and predicts worker movement paths. The fleet manager handles mixed human-robot scheduling with real-time replanning. Instead of selling robots that need empty zones, you could offer systems that fit into existing operations with workers already on the floor.

Manufacturing and assembly

any

Target: Factory operators transitioning from manual to semi-automated production lines

If you are a manufacturer adding robots to your shop floor but worried about worker safety compliance — this project developed AR-based interaction concepts that give workers real-time awareness of robot positions and tasks, plus human-aware planning algorithms that make robots adjust their routes based on where people are. The 6-partner consortium across 3 countries tested these in warehouse settings, but the same safety vest and planning technology applies to any mixed human-robot environment.

Frequently asked

Quick answers

What would this cost to implement in my warehouse?

The project data does not include specific pricing or implementation costs. The core components are a safety vest (wearable hardware), fleet management software, and AR interface — each would need licensing or purchase arrangements with the consortium partners. Contact the coordinator for commercial terms.

Can this scale to very large warehouses?

Scalability was a core design goal. The objective explicitly states the system targets large-scale flexible warehouses and developed multi-objective multi-constrained large-scale planning algorithms. The fleet manager handles heterogeneous fleets of both robots and humans with real-time reactive replanning.

What about IP and licensing — who owns the technology?

The project was funded as a Research and Innovation Action (RIA) coordinated by Karlsruhe Institute of Technology in Germany, with 6 partners across 3 countries. IP ownership typically follows EU grant rules where each partner owns the results they generated. Licensing would need to be negotiated with the relevant consortium members.

Is this certified for workplace safety regulations?

The project explicitly aimed to develop a certifiable safety concept based on the safety vest. This means the system was designed with certification in mind, but based on available project data, actual regulatory certification status is not confirmed. You would need to verify current certification with the consortium.

How long would it take to deploy in an existing warehouse?

The project ran from 2016 to 2020 and produced both prototype and final demonstrators for its key components including AR interaction, fleet planning, and safety systems. Based on available project data, specific deployment timelines for commercial installations are not documented. Integration complexity depends on your existing infrastructure.

Does it work with robots I already have?

The fleet manager was designed for heterogeneous fleets, meaning it coordinates different types of robots and human workers together. The safety vest concept works independently of specific robot brands since it makes the human detectable rather than requiring specific robot modifications. Integration details would depend on your current setup.

What kind of support is available?

The consortium includes 2 industrial partners alongside 3 universities and 1 research organization across Germany, Czech Republic, and Croatia. The coordinator is Karlsruhe Institute of Technology (KIT) in Germany. Post-project support availability would need to be confirmed directly with KIT or the industrial partners.

Consortium

Who built it

The SafeLog consortium is a compact team of 6 partners across 3 countries — Germany, Czech Republic, and Croatia. It is led by Karlsruhe Institute of Technology (KIT), one of Germany's top technical universities with strong robotics credentials. The consortium includes 2 industrial partners (33% industry ratio) alongside 3 universities and 1 research organization, but notably has zero SMEs. This academic-heavy composition means the technology is research-grade and well-documented, but may need a commercial partner to bring it to market. For a business looking to adopt this, expect to work with university tech transfer offices rather than a turnkey vendor — which means more flexibility in licensing but potentially longer time to a production-ready product.

KARLSRUHER INSTITUT FUER TECHNOLOGIECoordinator · DE
KONCAR INSTITUT ZA ELEKTROTEHNIKU D.O.O.participant · HR
SVEUCILISTE U ZAGREBU FAKULTET ELEKTROTEHNIKE I RACUNARSTVAparticipant · HR
CESKE VYSOKE UCENI TECHNICKE V PRAZEparticipant · CZ

How to reach the team

Karlsruhe Institute of Technology (KIT), Germany — reach out through their technology transfer office or the project website contact page

Order a report on this consortium See KARLSRUHER INSTITUT FUER TECHNOLOGIE profile →

Next steps

Talk to the team behind this work.

Want to connect with the SafeLog team for licensing or pilot discussions? SciTransfer can organize an introduction and help you evaluate fit for your warehouse operations.

Order a report on this topic More in Manufacturing & Industry 4.0