The risk of falling from a tailgate lifter (TGL) arises when an operator moves up and down the platform while on board, particularly when supporting roll box pallets (RBPs) to keep them steady. Recent revisions in the ordinance on industrial safety and health assert that, in principle, operators are not permitted to move up and down on the platform. Despite instruction manuals from manufacturers advising against operating TGLs on inclined surfaces, the intrinsic drainage slope on roads constantly poses a risk of overrun for RBPs and other carts during transit. This is especially concerning on roadways where slight inclination can cause the carts to shift uncontrollably, risking occupational accidents and cargo damage. To address these concerns, we evaluated the efficacy of various overrun prevention tools with a caster locking and provided requirements for effective overrun prevention measures, which were approved by the committee composed of experts.
 Our findings suggest that an equilateral triangular prism — fabricated from rubber and featuring a 60° angle on all three sides where the caster wheel makes contact — is the most viable solution. The dimensions play a critical role; a height of 30 mm or more ensures that the caster wheels cannot surmount the tool having a performance under practical operational conditions. Furthermore, the ease of tool placement, especially when pressed against the caster wheel with a foot, is greatly facilitated with a rubber with a hardness of approximately 80. For enhanced visibility in low-light conditions or during nighttime operations, selecting yellow or orange for the tool color is advised because of their high contrast against the TGL platform, thereby enhancing safety measures. Through these findings, a clear pathway toward minimizing the risk of overrun incidents during TGL operations is elucidated, which, in turn would significantly mitigate the associated occupational hazards.