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 catostrophic fall is ever-present. Accidental falls are not just a leading cause of warehouse injuries; they are among the most severe, often resulting in work stoppages, high compensation costs, and, most importantly, lasting human impact. Yet, with the right precautions and technology, these incidents are able to be prevented.

The Reality of Falls from Heights

Falls from elevated surfaces, such as elevated vehicles, 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 compliance alone does not guarantee safety. In practice, even veteran employees can become overconfident or hurried, leading to neglecting to connect safety equipment. The consequences are sobering: a single miscalculation at height can result in life-altering injuries or fatalities.

Warehouses are busy settings. Workers frequently need 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 introduce unique fall hazards. A momentary lapse, not attaching a lanyard or not fastening a harness properly, can have serious consequences.

Ordinary Fall Protection: Strengths and Shortcomings

In the past, warehouses have relied on a mix of guardrails, safety nets, and personal fall arrest solutions to protect employees at height. Guardrails and barriers are effective on mezzanines and fixed platforms, but they do not protect 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 solutions depend on workers always following procedures. Even the best-trained employee can neglect to connect a harness when rushed, particularly during peak periods or under tight deadlines.

Safety managers have long struggled with this human factor. Spot checks and periodic audits are useful, but they don't guarantee 100% compliance, especially in large or multi-shift operations.

The Raymond iWarehouse Integrated Tether System: Compliance Made Easy

Raymond’s iWarehouse Integrated Tether System is a significant step forward for fall prevention for operations where elevated work is common. Unlike traditional systems that depend only on workers following procedures, the Integrated Tether System employs wireless technology to make sure 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 operate at normal speed or allow the forks to elevate. If the operator is not properly tethered, the system immediately sends a series of progressive warnings including sound warnings, flashing signals on the display, and, if ignored, reducing speed and disabling elevation features. This comprehensive system makes sure that employees cannot skip safety steps, even unintentionally.

The Integrated Tether System is now 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 instant monitoring, the system supplies managers with compliance tracking and reporting, allowing for specific safety education and preventive safety planning.

Take the Next Step Toward Fall Protection

Falls from heights remain as one of the most serious hazards in today’s warehouses, but they are also one of the most preventable. By adding modern technology such as the Integrated Tether System to your safety program, you can achieve real safety improvements, protecting your people, your output, and your peace of mind.

If you’re ready to improve your fall prevention efforts, contact Raymond West. Our safety experts can help you assess your current risks, bring in cutting-edge solutions, and develop a stronger safety culture—one where every worker at height is protected on every shift.

Raymond West's Calexico facility serves Imperial County and Yuma County, Including Calexico, Brawley, El Centro, San Luis, Yuma and surrounding areas.

Raymond West | Calexico Material Handling Equipment Supplier

285 Rood Rd
Calexico, CA 92231
(760) 768-8700