High-bay racking scenarios usually feature narrow operating aisles, extreme lifting heights and dense stored goods, which put forward higher requirements for the accuracy, stability and safety awareness of electric forklift operators. A standardized systematic training system can effectively reduce operational risks, avoid goods damage and personnel injury, and maintain stable warehouse operation.

Before launching targeted training, the management team needs to complete pre-qualification verification for all trainees first. All trainees must have mastered basic common electric forklift operation skills, passed the basic safety assessment for general warehouse scenarios, and be familiar with basic warehouse facilities, including emergency exits, load limit marking areas, and power supply distribution zones. Operators who do not meet the pre-qualification requirements cannot participate in subsequent high-bay racking work training directly.

The first formal training module is targeted theoretical learning. The training content covers the special rules exclusive to high-bay racking operation, including the rated load limit of goods at different rack heights, the minimum safety clearance requirement for narrow aisles, the gravity shift principle of the whole machine when the fork is lifted to ultra-high positions, the influence of ground flatness on high-lift operation stability, as well as the correct use method of the limit alarm device and surrounding monitoring system in the working area. Trainees need to clearly know that it is forbidden to overload the goods for lifting, it is forbidden to carry personnel on the fork, and it is forbidden to stand under the lifted fork at any time.

The second module is staged practical training. The first stage is low-speed adaptation practice in an empty simulated high-bay operation area, without carrying any goods, to help trainees get familiar with the precise control of steering, forward and backward movement, and fork lifting and lowering, to adapt to the high precision operation requirements of narrow aisle scenarios. The second stage is low-height goods picking and placing practice, trainees will gradually increase the lifting height after they can complete 20 consecutive no-error operations, until they can accurately align the goods with the high-level rack position and place the goods stably. A certified experienced supervisor needs to stand by the whole process, and correct wrong operations such as sharp steering, moving the vehicle at high speed when the fork is lifted in time.

The third module is emergency scenario simulation training. Trainees will learn the correct disposal process when facing slight vehicle tilt, high-position goods offset, and sudden obstacles in the aisle, master the operation of lowering the fork slowly, stopping the vehicle stably, and reporting to the management personnel immediately, and it is clearly required that operators can not dispose of hidden risks without authorization.

After all training modules are completed, trainees need to pass both theory assessment and practical assessment to get the operation qualification. The team will also organize a regular re-training and skill verification every 6 months, to help operators maintain good operation habits for a long time.