. Purpose
This standard operating procedure is formulated to regulate inbound, outbound, forklift operation, inspection and maintenance activities for drive-in and drive-through racking systems. It aims to eliminate risks including rack deformation, pallet drop-off, collision and structural collapse, and guarantee the safety of warehouse staff and stored goods.
2. Scope
This SOP applies to all rack lanes, forklifts, pallets and relevant operators within the warehouse. Only full-pallet loading and unloading are permitted. Case picking or de-stacking inside rack tunnels is prohibited.
3. Basic Stock Rotation Rules
Single-end drive-in rack: Follow LIFO (Last In First Out) principle. Outer pallets must be removed first to access pallets stored deep inside the lane.
Double-end drive-through rack: Follow FIFO (First In First Out) principle. Goods are loaded from one end and unloaded from the opposite end.
This racking type is designed for bulk storage of single SKU. It is not suitable for multi-SKU, small-batch inventory or goods with strict expiry date control.
Pallet size and load rating must be unified. Mixing pallets of different dimensions is not allowed.
4. Pallet Requirements
The actual load on each pallet shall never exceed the rated capacity of the corresponding rack level. Overloading is strictly forbidden.
Pallets must be intact without broken runners or cracks. Pallet bottom runners shall rest evenly and centrally on support rails. Any pallet overhang is prohibited.
Cargo on pallets shall be stacked neatly with balanced weight and centered gravity. Offset or lopsided loading is not permitted.
Pallets used in cold storage shall be low-temperature resistant, moisture-proof and anti-brittle.
5. Inbound Procedure
Only certified forklift operators are allowed to perform the operation. Confirm lane number, storage level and item information before entering the tunnel. Approach the rack squarely; angled entry is forbidden.
Lift the pallet approximately 20 mm above the support rails, travel slowly and steadily into the lane. Sudden acceleration, emergency braking or steering inside the lane is prohibited.
Start loading from the deepest position of the lane and fill the lane from inner side to outer side sequentially.
Lower the pallet gently onto both support rails. Verify the pallet is centered, free of jamming and fully supported.
After the pallet is securely seated, back the forklift out straight at low speed. Steering inside the storage tunnel is forbidden.
Update inventory records or WMS system once loading is completed.
6. Outbound Procedure
Under LIFO mode, always pick the outermost pallet first. If an inner pallet needs to be retrieved, remove all front pallets to a safe staging area in advance.
Drive the forklift squarely into the lane, insert forks into the target pallet and lift steadily until the pallet is completely clear of support rails.
Back straight out of the lane. Steering can only be carried out after the forklift fully exits the rack tunnel.
Check item, batch number and quantity, then complete outbound registration.
Return pallets from staging area back to their original outer positions after picking work finishes.
7. Forklift Safety Regulations
Maintain walking speed inside rack lanes. Reach trucks are the recommended equipment for this racking system.
It is forbidden to carry passengers, stand inside lanes, break down pallets or place temporary materials within rack tunnels.
Guide rails and rearview mirrors are suggested for deep lanes with poor visibility. Operators shall receive specialized training regularly.
Do not push, pry rack components or pallets using forklifts. Sliding pallets along support rails is prohibited.
If bent rack members, loose bolts or damaged rails are found, stop all operations in that lane immediately and report to the supervisor.
8. Routine Inspection & Maintenance
Daily pre-shift inspection: Check uprights, post protectors, support rails and support arms for collision damage or bending; check tightness of anchor bolts.
Monthly comprehensive inspection: Inspect diagonal bracing, tie rods, connectors and coating condition. Extra rust inspection is required for cold storage applications.
Professional structural inspection by rack supplier every 6 months with formal inspection report issued.
Any rack component with damage must be taken out of service. Unauthorized on-site welding, cutting or reinforcement is forbidden. Replacement shall be arranged by the rack manufacturer.
Replace damaged post protectors promptly. Touch up scratched paint surfaces to avoid rusting.
9. Prohibited Actions
Overloading, adding extra storage levels without engineering approval
Pallet overhang, offset loading or suspended pallets
Speeding, steering or hitting rack structures inside lanes
Personnel entering storage tunnels (forklift operation only)
Unauthorized rack modification, cutting or welding without supplier structural calculation
Placing goods directly on support rails without pallets
10. Emergency Response
Jammed or fallen pallet: Stop operation immediately, barricade the affected lane, isolate the hazard zone and report to supervisor. Forcible dragging is forbidden. Only trained personnel are allowed to handle the issue.
Rack deformation after impact: Lock out the whole lane with warning signs, clear surrounding area and contact rack supplier for structural assessment.
Personnel injury: Cease all nearby operations immediately, provide first aid and submit accident report.
11. Training & Documentation
All forklift operators assigned to drive-in / drive-through racking must complete dedicated training and pass assessment. Training logs, inspection checklists and professional inspection reports shall be filed and retained for review.
Warning Sign Text (for rack entrance)
⚠️ Drive-In Racking: LIFO Rule. Full pallet operation only. No overload, pallet overhang or steering inside lane.
Industry Insights