If you're a warehouse manager, you know the risks that are inherent with elevated work. Whether picking stock from upper shelves or using an order picker on an elevated platform, the threat of a serious fall is always looming. Falls from heights are not just one of the main causes of injuries in warehouses; they are among the most severe, often resulting in work stoppages, expensive insurance claims, and, most importantly, permanent effects on people. Yet, with the right approaches and technology, these incidents are avoidable.

The Reality of Falls from Heights

Falls from elevated surfaces, such as elevated vehicles, raised work areas, 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 simply following the rules doesn’t ensure safety. In practice, even seasoned workers can become overconfident or rushed, leading to forgetting to use safety harnesses. The outcome can be grave: one miscalculation at height can result in catastrophic harm or fatalities.

Warehouses are dynamic environments. Workers frequently need to access inventory stored several levels above the ground, using equipment like order pickers or turret trucks. These machines are crucial for today’s warehouses, but they also create special safety challenges. A single lapse, not attaching a lanyard or improperly securing a lanyard, can have devastating effects.

Traditional Fall Protection: Strengths and Shortcomings

In the past, warehouses have employed a mix of protective rails, safety nets, and personal fall arrest solutions to protect employees at height. Barriers and guardrails are effective on mezzanines and fixed platforms, but they do not protect operators of moving vehicles. Personal fall arrest systems such as lanyards and harnesses are the go to solution for employees on mobile lifts. Unfortunately, these systems rely on workers always following procedures. Even the most conscientious employee can neglect to connect a harness when rushed, particularly during peak periods or under tight deadlines.

Safety managers have long wrestled with the challenge of human error. Spot checks and routine audits are useful, but they don't guarantee 100% compliance, 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 represents a leap forward in fall protection for warehouse environments where elevated work is common. In contrast to traditional systems that count on human compliance, the Integrated Tether System employs wireless technology to make certain that safety standards 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 secure a tether 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 instantly sends a series of increasing notifications including sound warnings, visual warnings on the iMONITOR display, and, if ignored, reducing speed and disabling elevation features. This comprehensive system makes sure that workers 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. Besides real-time monitoring, the system provides managers with detailed data on tether compliance, enabling specific safety education and proactive safety management.

Take the Next Step Toward Fall Protection

Falls from heights are a major risk in warehouse operations, but they are also among the most avoidable. By adopting new tools like the Integrated Tether System, you can achieve real safety improvements, protecting your employees, your operations, and your peace of mind.

If you’re ready to make safety a priority, contact Raymond West. Our warehouse safety professionals can review your safety needs, bring in cutting-edge solutions, and build a safer, more resilient operation—one where every worker at height returns safely to the ground.

Raymond West's San Diego facility serves all of San Diego County, including Carlsbad, Chula Vista, Downtown, El Cajon, Escondido, Fenton Carroll Canyon, Grantville, Kearney Mesa, Levanto, Morena, National City, Oceanside, Otay, Otay Mesa, Poway, San Marcos, Santee, Sorrento Mesa, Spring Valley, Vista and all surrounding areas.

Raymond West | San Diego Material Handling Equipment Supplier

8221 Arjons Dr # B2
San Diego, CA 92126
(858) 679-1800