Efficient and Safe
Order Picking in High-Rise Shelving Systems

Order Picker are vital tools in warehouses and distribution centers, allowing workers to retrieve products from high storage areas. Safe operation involves understanding the load capacity, proper positioning of the picker, and the correct use of personal protective equipment (PPE) to prevent falls or injuries when retrieving orders.

Picker Setup
& Controls

Learn how to prepare and inspect an Order Picker before use, including control checks and safety gear requirements.

Safe
Operation Tips

Discover safe driving techniques, proper load handling, and movement protocols when using an Order Picker at height.

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Order Picker Resources & Guides

Order Picker Operation: Safety at Every Level

Operating an order picker is not just about moving through warehouse aisles it's about working at height with precision, awareness, and responsibility. At GamaSafety, we train operators to safely handle elevated equipment while navigating the unique hazards associated with vertical movement, narrow aisle operation, and manual item retrieval.

ORDER PICKER

Order Picker Safety Overview:
Usage Safety and Risk Prevention.

Operating an Order Picker requires a strong understanding of safety practices and risk prevention strategies. These machines are essential in warehouses and distribution centers, allowing workers to access elevated storage racks efficiently. However, due to their design and height capabilities, improper use can result in serious incidents, including falls, collisions, or product damage.

To ensure safe operation, all operators must receive proper training, including hazard recognition, fall protection awareness, and correct use of controls. Regular inspections, adherence to manufacturer guidelines, and use of personal protective equipment (PPE) are also critical components of safe order picker use.

Understanding site-specific hazards, maintaining clear communication in the work area, and never exceeding weight limits are key best practices. At Gama Safety, we emphasize not just compliance with Canadian regulations, but also a proactive approach to workplace safety empowering workers to operate Order Pickers confidently and responsibly.

Efficient and Safe
Order Picking in High-Rise Shelving Systems

Order Picker are vital tools in warehouses and distribution centers, allowing workers to retrieve products from high storage areas. Safe operation involves understanding the load capacity, proper positioning of the picker, and the correct use of personal protective equipment (PPE) to prevent falls or injuries when retrieving orders.

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ORDER PICKER Definition

What is an Order Picker?

An Order Picker is a type of powered industrial truck used primarily in warehouse and logistics environments to lift operators to elevated storage locations. Unlike standard forklifts, where the load is lifted independently, order pickers raise both the operator and the forks to heights often ranging from 4 to 9 meters or more, allowing workers to manually pick individual items or cases from high racking systems.

These machines are designed for "piece picking" rather than full pallet transport, making them essential in fulfillment centers, e-commerce operations, and retail distribution warehouses where speed, precision, and high-level access are critical.

Due to their vertical lift capability, fall protection systems are mandatory, and operators must be trained in both material handling and working at heights. Safe operation involves a unique combination of skills: vertical navigation, balance management, precision control, and risk awareness.

How Order Pickers Differ from Forklifts

While often confused with standard forklifts, order pickers have distinct characteristics that set them apart, especially in function and risk profile.

Key differences include:

  • The operator platform elevates with the forks, increasing exposure to fall hazards.

  • Order pickers are designed for individual item selection, not pallet transport.

  • They operate within narrow aisle configurations (NA trucks), requiring tighter control and spatial awareness.

  • They typically have lower lifting capacities but higher vertical reach.

Because of these differences, specific training is required. General forklift certification does not automatically qualify a worker to operate an order picker. At GamaSafety, we provide focused instruction tailored to this equipment's unique demands.

Applications and Work Environments

Order pickers are commonly used in:

  • High-density warehouses with multi-tier racking systems

  • E-commerce distribution centers where orders are fulfilled by picking small items

  • Retail logistics facilities where diverse inventory must be accessed efficiently

  • Automotive parts warehouses, pharmaceutical storage, and cold chain environments

In these settings, the order picker helps improve productivity by giving workers direct access to high-level inventory, eliminating the need for ladders or mezzanine platforms. However, this access comes with increased risk, which makes operator training and safety system integration essential.

Main Components of an Order Picker

Understanding each component is essential for safe and effective operation. Key parts include:

  • Operator Platform: The area where the operator stands, which elevates during use.

  • Mast & Hydraulic Lift Cylinder: Enables vertical movement of the platform.

  • Forks: Hold and support loads; may also rise with the operator.

  • Fall Arrest Anchor Point: Connection point for personal fall protection gear.

  • Control Panel: Includes joystick, throttle, lift/lower controls, and emergency stop.

  • Drive Unit: Provides propulsion and steering—usually electric-powered.

  • Battery Pack: Typically rechargeable lead-acid or lithium-ion batteries.

At GamaSafety, operators receive hands-on practice with all critical components and learn how to conduct pre-use inspections and recognize mechanical faults.

Why Specialized Training Is Essential

Order pickers are classified as high-risk equipment because they elevate the worker during operation. This creates unique hazards including falls from height, equipment tipping, operator ejection, and injury from load shift or misplacement.

Training must address:

  • Fall arrest system usage

  • Load placement and balance

  • Speed control and maneuverability in elevated positions

  • Emergency lowering and rescue protocols

  • CSA-compliant operating procedures

At GamaSafety, our Order Picker Training is built around real-life scenarios, equipment walkarounds, practical skill assessments, and full integration of Canadian safety laws. Certification ensures that workers are legally cleared and fully prepared to perform this specialized role safely.

ORDER PICKER Legislation

Operator Training Requirements Under Canadian Law

In Canada, provincial occupational health and safety regulations mandate that any worker operating a powered lift truck—such as an order picker—must be trained, evaluated, and certified before using the equipment.

Key training requirements include:

  • A classroom-based theory component

  • A hands-on practical evaluation under realistic conditions

  • Instruction in hazard identification, emergency procedures, and equipment inspection

  • Proof of fall protection training if the equipment elevates the worker

Employers must ensure workers are trained on the specific class of equipment being used. GamaSafety's course complies with these requirements and delivers legally recognized certification upon successful completion.

CSA B335-15 Compliance and National Standards

The Canadian Standards Association (CSA) B335-15 is the nationally recognized benchmark for lift truck safety training and equipment operation. It outlines the requirements for:

  • Instructor and evaluator qualifications

  • Competency testing and pass/fail standards

  • Program content and duration

  • Refresher training intervals (recommended every 3 years or sooner)

  • Maintenance and inspection protocols

  • Operator behavior and safe work practices

GamaSafety's Order Picker Training fully complies with CSA B335-15 and integrates content from CSA Z259 when fall protection systems are involved.

Working at Heights & Fall Protection Legislation

Because the operator platform on an order picker elevates above 3 meters, operators are considered to be “working at heights”, and must follow provincial fall protection legislation.

Examples include:

  • Ontario Regulation 213/91 – Construction Projects

  • CSA Z259 Series – Fall Protection Equipment Standards

  • Federal COHS Regulations, Part XII – PPE and Fall Protection

Workers must:

  • Use an approved full-body harness and lanyard

  • Attach to a fixed anchor point built into the machine

  • Be trained in emergency procedures and rescue protocols

GamaSafety incorporates fall protection modules directly into the course content, ensuring full legal compliance.

Employer Responsibilities and Legal Liability

Canadian law places clear responsibility on employers to ensure:

  • All order picker operators are properly trained and certified

  • Fall protection equipment is provided, inspected, and maintained

  • Operators are supervised, especially during elevated tasks

  • All training is documented and retained

  • Refresher training is provided after incidents or unsafe behavior

Failure to meet these obligations may result in significant penalties under provincial laws. At GamaSafety, we help companies meet these responsibilities through structured training, documentation support, and legal compliance resources.

Recordkeeping and Proof of Certification

According to CSA B335-15 and provincial OHS regulations, employers must keep detailed records of all operator training, including:

  • Full name of the operator

  • Type and class of equipment trained on

  • Date and location of training

  • Trainer’s qualifications

  • Evaluation results

  • Certificate expiration date

  • Proof of fall protection competency

GamaSafety provides professional certification cards and course documentation that meets audit standards. We also offer renewal tracking and optional reminders to ensure you stay compliant.

Other Courses You May Be Interested In.

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