Most warehouse managers are aware of the hazards that come with working at heights. Whether picking stock from upper shelves or using an order picker on an elevated platform, the potential of a serious fall is ever-present. Falls from heights are not just one of the main causes of injuries in warehouses; they are some of the most devastating, often resulting in lost time, costly claims, and, most importantly, permanent effects on people. Yet, with the right precautions and technology, these incidents are preventable.

The Dangers of Elevated Work

Falls from high locations, such as lift trucks, elevated platforms, and mezzanines account for a substantial number of warehouse injuries. OSHA mandates fall protection at elevations of four feet or more in general industry settings, but meeting regulations isn’t always enough. In practice, even experienced operators can become overconfident or pressed for time, leading to forgetting to use safety harnesses. The consequences are serious: one misstep at height can result in significant bodily harm or fatalities.

Warehouses are dynamic environments. Workers frequently need to access inventory stored several levels above the ground, using equipment like swing-reach vehicles or turret trucks. These machines are essential for modern fulfillment operations, but they also create special safety challenges. A momentary lapse, not attaching a lanyard or improperly securing a lanyard, can have serious consequences.

Traditional Fall Protection: Strengths and Shortcomings

Historically, warehouses have employed a mix of guardrails, safety nets, and personal fall arrest systems to protect employees at height. Guardrails and barriers are useful for fixed elevated areas, but they cannot ensure the safety of operators of moving vehicles. Personal fall arrest systems such as harnesses and lanyards are the go to solution for operators of order pickers and similar vehicles. Unfortunately, these systems rely on consistent human behavior. Even the best-trained worker can miss a step while distracted, particularly during busy shifts or under tight deadlines.

Supervisors have long wrestled with the challenge of human error. Visual checks and periodic audits can assist, but they don't guarantee 100% compliance, especially in large or multi-shift operations.

The Raymond iWarehouse Integrated Tether System: Closing the Compliance Gap

Raymond’s iWarehouse Integrated Tether System is a leap forward in fall protection for operations where work at height is routine. Unlike traditional systems that count on human compliance, the Integrated Tether System employs wireless technology to ensure that safety protocols are met each time someone operates a lift truck.

Here's what happens: The system requires the worker to attach a lanyard to their safety harness before the vehicle will move at full capacity or allow the forks to elevate. If the operator is not properly tethered, the system instantly sends a series of escalating alerts including beeping alerts, visual warnings on the iMONITOR display, and, if unaddressed, slowing the vehicle to a crawl and shutting off lift controls. This multi-layered approach makes sure that operators cannot bypass safety procedures, even unintentionally.

The Integrated Tether System is currently available for Raymond’s Orderpicker models (5300, 5400, 5500, 5600) and Swing-Reach trucks (9600, 9700), making it a versatile choice for many facilities. In addition to instant enforcement, the system provides supervisors with detailed data on tether compliance, allowing for focused coaching and proactive safety management.

Take the Next Step Toward Fall Protection

Falls from heights are a top safety concern for modern warehouses, but they are also one of the most avoidable. By integrating advanced solutions like the Raymond Integrated Tether System into your safety strategy, you can go further than just meeting regulations, protecting your team, your output, and your sense of security.

If you’re ready to take a proactive approach to fall protection, contact Raymond West. Our safety experts can help you assess your current risks, install advanced safety systems, and develop a stronger safety culture—one where every worker at height comes down safely, every time.

Raymond West's Fremont facility serves all of the Bay Area, including San Francisco, Oakland, San Leandro, Hayward, Union City, Fremont, San Jose, Santa Clara, Mountain View, Palo Alto, Redwood City, San Mateo, South San Francisco, Richmond, Vallejo, Concord, Pleasanton, Livermore and all surrounding areas.

Raymond West | San Francisco Bay Area Material Handling Equipment Supplier

41400 Boyce Rd
Fremont, CA 94538
(800) 675-2500