If you're a warehouse manager, you know the risks that are inherent with working at heights. Whether retrieving inventory from a high rack or operating an order picker on a mezzanine, the threat of a serious fall is always looming. Falls from heights are not just a top reason for warehouse accidents; they are some of the most serious, often resulting in lost time, costly claims, and, most importantly, long-term consequences for workers. Yet, with the right strategies and technology, these incidents are avoidable.

The Reality of Falls from Heights

Falls from raised platforms, such as lift trucks, elevated platforms, 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 meeting regulations isn’t always enough. In practice, even seasoned workers can become overconfident or pressed for time, leading to forgetting to use safety harnesses. The consequences are grave: a single miscalculation at height can result in catastrophic harm or fatalities.

Warehouses are busy settings. Employees are often required to retrieve goods from high shelves, using equipment like lift trucks or turret trucks. These machines are essential for modern fulfillment operations, but they also create special safety challenges. A single lapse, failing to secure safety gear or improperly securing a lanyard, can have tragic results.

Traditional Fall Protection: Strengths and Shortcomings

Historically, warehouses have relied on a mix of protective rails, safety nets, and personal fall arrest systems to protect workers at height. Guardrails and barriers are effective on mezzanines and fixed platforms, but they cannot protect workers on mobile equipment. Personal fall arrest systems such as lanyards and harnesses are the most common strategy for workers using elevated trucks. Unfortunately, these solutions rely on reliable use by staff. Even the best-trained employee can forget to tether in a moment of distraction, especially during peak periods or under demanding workloads.

Supervisors have long found it difficult to manage this risk. Visual checks and periodic audits are useful, but they don't provide total assurance, especially in big warehouses or places with many shifts.

The Raymond iWarehouse Integrated Tether System: Reducing the Compliance Burden

Raymond’s iWarehouse Integrated Tether System is a significant step forward for fall prevention for operations where elevated work is the norm. Unlike traditional systems that count on human compliance, the Integrated Tether System uses modern connectivity to make certain that safety standards are followed every time an operator steps onto an order picker or swing-reach truck.

Here's what happens: The system requires the employee to connect a self-retracting lanyard to their harness before the vehicle will move at full capacity or allow the forks to elevate. In the event that the worker isn't tethered correctly, the system immediately triggers a series of increasing notifications including beeping alerts, visual warnings on the iMONITOR display, and, if unaddressed, reducing speed and disabling elevation features. This layered safety method ensures 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 practical solution for a wide range of warehouse operations. In addition to real-time enforcement, the system supplies supervisors with insights into safety behavior, enabling specific safety education and forward-thinking risk management.

Take the Next Step Toward Fall Protection

Falls from heights remain as a major risk in warehouse operations, but they are also among the most easily mitigated. By integrating advanced solutions like the Raymond Integrated Tether System into your safety strategy, you can go further than just meeting regulations, protecting your employees, your output, and your sense of security.

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

Raymond West's Ontario, California facility serves parts of Los Angeles County and San Bernardino County, including Ontario, Fontana, Rancho Cucamonga, Upland, La Verne, San Dimas, Covina, West Covina, Pomona, Diamond Bar, Rowland Heights, Chino, Norco, Eastvale, Corona, Jurupa Valley, San Bernardino, Rialto and all surrounding areas.

Raymond West | Ontario California Material Handling Equipment Supplier

4602 E Brickell St
Ontario, CA 91761
(909) 930-9399