Every warehouse manager knows the hazards that are inherent with working at heights. Whether picking stock from upper shelves or using an order picker on an elevated platform, the threat of a serious fall is ever-present. Falls from heights are not just a top reason for warehouse accidents; they are among the most serious, often resulting in lost time, expensive insurance claims, and, most importantly, long-term consequences for workers. Yet, with the right strategies and technology, these incidents are preventable.

The Dangers of Elevated Work

Falls from raised platforms, such as order pickers, mezzanines, 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 seasoned workers can become careless or pressed for time, leading to forgetting to use safety harnesses. The consequences are serious: one misstep at height can result in life-altering injuries or fatalities.

Warehouses are dynamic environments. Employees frequently need to reach stock stored high above the floor, 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, not attaching a lanyard or not fastening a harness properly, can have tragic results.

Ordinary Fall Protection: Strengths and Shortcomings

Historically, warehouses have employed a mix of guardrails, safety nets, and personal fall arrest solutions to protect workers performing their duties up high. Barriers and guardrails are useful for fixed elevated areas, but they cannot protect workers on order pickers. Personal fall arrest systems such as lanyards and harnesses are the go to solution for employees on mobile lifts. Unfortunately, these solutions depend on consistent human behavior. Even the best-trained worker can neglect to connect a harness when rushed, especially during peak periods or under production pressure.

Supervisors have long wrestled with the challenge of human error. Visual checks and periodic audits help, but they don't provide total assurance, especially in complex, round-the-clock facilities.

The Raymond iWarehouse Integrated Tether System: Reducing the Compliance Burden

Raymond’s iWarehouse Integrated Tether System is a leap forward in fall protection for warehouse environments where work at height is common. In contrast to traditional systems that depend only on workers following procedures, the Integrated Tether System uses wireless technology to make sure that safety protocols are followed every time an operator steps onto an order picker or swing-reach truck.

It works in the following way: The system requires the worker to connect a self-retracting lanyard to their harness before the vehicle will function at regular speed or allow the forks to elevate. In the event that the worker isn't tethered correctly, the system instantly fires off a series of increasing notifications including sound warnings, on-screen messages, and, if ignored, slowing the vehicle to a crawl and shutting off lift controls. This comprehensive system ensures that workers cannot work around required protocols, 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 practical solution for a wide range of warehouse operations. Besides 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

Elevated falls remain as a major risk in warehouse operations, but they are also one of the most preventable. By adopting new tools like the Integrated Tether System, you can go further than just meeting regulations, protecting your employees, your operations, and your sense of security.

If you’re ready to improve your fall prevention efforts, contact Raymond West. Our safety experts can help you assess your current risks, implement the latest technology, and build a safer, more resilient operation—one where every worker at height returns safely to the ground.

Raymond West's Orange County service area includes Anaheim, Costa Mesa, Fullerton, Garden Grove, Orange, Santa Ana, Tustin and all surrounding areas.

Raymond West | Orange County Material Handling Equipment Supplier

Orange County, CA
(714) 790-9300