If you're a warehouse manager, you know the hazards that come with elevated work. Whether retrieving inventory from a high rack or operating an order picker on a mezzanine, the threat 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 severe, often resulting in work stoppages, costly claims, and, most importantly, long-term consequences for workers. Yet, with the right approaches and technology, these incidents are preventable.

The Reality of Falls from Heights

Falls from high locations, such as lift trucks, mezzanines, and mezzanines account for a large portion of warehouse injuries. OSHA mandates fall protection at elevations of four feet or more in general industry settings, but simply following the rules doesn’t ensure safety. In practice, even seasoned workers can become complacent or rushed, leading to lapses in tethering or harness use. The outcome can be grave: one misstep at height can result in significant bodily harm or fatalities.

Warehouses are constantly changing workplaces. Employees frequently need to access inventory stored several levels above the ground, using equipment like lift trucks or turret trucks. These machines are crucial for today’s warehouses, but they also bring new risks for falls. A single lapse, not attaching a lanyard or not fastening a harness properly, can have tragic results.

Traditional Fall Protection: Strengths and Shortcomings

In the past, warehouses have employed a mix of safety barriers, safety nets, and personal fall arrest systems to protect employees at height. Guardrails and barriers are effective on mezzanines and fixed platforms, but they do not protect workers on mobile equipment. Personal fall arrest systems such as harnesses and lanyards are the go to solution for operators of order pickers and similar vehicles. Unfortunately, these solutions depend on workers always following procedures. Even the most conscientious employee can forget to tether in a moment of distraction, particularly during busy shifts or under demanding workloads.

Supervisors have long wrestled with the challenge of human error. Spot checks and routine audits are useful, but they cannot provide total assurance, especially in big warehouses or places with many shifts.

The Raymond iWarehouse Integrated Tether System: Closing the Compliance Gap

Raymond’s iWarehouse Integrated Tether System is a significant step forward for fall prevention for warehouse environments where elevated work is common. Unlike traditional systems that rely solely on operator diligence, the Integrated Tether System employs modern connectivity to make sure that safety protocols are followed every time an operator steps onto an order picker or swing-reach truck.

Here’s how it works: The system requires the employee to connect a self-retracting lanyard to their harness before the vehicle will operate at normal speed or allow the forks to elevate. In the event that the worker isn't tethered correctly, the system instantly sends a series of increasing notifications including sound warnings, on-screen messages, and, if unaddressed, automatic reduction of the vehicle’s speed to a crawl and disabling of lift functions. This multi-layered approach ensures that employees cannot bypass safety procedures, even unintentionally.

The Integrated Tether System is now an option 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 compliance tracking and reporting, enabling specific safety education and forward-thinking risk management.

Take the Next Step Toward Fall Protection

Elevated falls are a top safety concern for modern warehouses, but they are also one of the most avoidable. By adopting new tools like the Integrated Tether System, you can move beyond compliance to true risk reduction, protecting your people, your output, and your sense of security.

If you’re ready to take a proactive approach to fall protection, contact Raymond West. Our safety expers can review your safety needs, install advanced safety systems, and develop a stronger safety culture—one where every worker at height returns safely to the ground.

Raymond West's Nogales facility serves Santa Cruz County and Pima County, including Nogales, Patagonia, Tucson, South Tucson, Marana, Oro Valley, Sahuarita and surrounding areas

Raymond West | Nogales Material Handling Equipment Supplier

480 N Mariposa Rd C
Nogales, AZ 85621
(520) 281-4125