Peak seasons are an exciting time for any business. These busy seasons can mean increased orders, fulfillment requests, and, best of all, revenue. But peak seasons can also be stressful times that lead to warehouse inefficiencies and cause lost opportunities. Lead time can get extended and damage your reputation if you haven’t planned effectively for a higher than normal volume. Here are three useful questions to ask as you prepare for your upcoming peak season:

Do I have the right equipment for increased velocity?

Sometimes the right warehouse equipment is a full sit-down forklift (like a 3-wheel electric) that can move large pallets of numerous individual products to high velocity picking areas. For other warehouses in peak seasons, versatile hand pallet or electric walkie pallet jacks that can quickly cover short distances with limited touches are the answer. But as you come into your peak season, take an inventory and make sure you have the right material handling equipment to get the job done.

Do I need to reorganize my warehouse during peak seasons?

Perhaps it makes sense to keep pallets of high velocity, peak season products on pallets near the shipping area. Or maybe high velocity products need to be placed on lower racking levels for easier access by forklift operators and order picking personnel. Your distribution and supply chain needs will dictate what you need, but it’s worth asking if you can reorganize to be more efficient during peak seasons.

Can I increase efficiency by cross docking?

The goal of any productive warehouse is to eliminate touches on each product. If you can decrease the number of times a product needs to be moved, then you can shorten your lead time for customer delivery. During high-demand periods, you might consider whether you have an opportunity for cross docking, or the process of receiving a product and then shipping it to its next location without ever moving it to short or long term storage in a warehouse. If peak seasons demand quick delivery of products, it might be best to grab a hand pallet or electric walkie pallet jack and immediately put that received product on the next truck for shipping.

Original Post: Jake Stewart, Digital Copywriter, Toyota Material Handling, USA

Let’s be honest. There are so many statistics and metrics involved with a forklift, it can be tough to understand what is what. There are tire types, mast types, various heights and dimensions that are all vital to know. Each of these needs consideration when considering what forklift is right for your operation.

One metric that is often overlooked is forklift free lift. A forklift’s free lift is the maximum height you can raise the forks without changing the mast height. There are two instances where this typically happens: when the inner mast rails extends past the outer mast rails or when the load backrest or carriage exceeds the height of the outer mast rails.

It is important to understand forklift free lift, especially if you are stacking or unstacking in confined spaces such as trailers, containers, and racking systems. These application have height restrictions and might cause product or equipment and possible safety concerns for operators or nearby pedestrians. There are two types of free lift a forklift can have: limited free lift or full free lift.

Forklift Free Lift – Limited Free Lift

When a forklift has limited free lift, it means that the inner mast rails will extend either immediately or shortly after lift is requested.  Limited free lift occurs with single-stage masts and two-stage masts with no free lift cylinder (see below on Full Free Lift). The amount of free lift can vary based on the condition and adjustment of the forklift’s lift chains as well as other factors such as fork thickness.

Forklift Free Lift – Full Free Lift

Full-free lift on a forklift means that the forks can be raised without immediately extending the inner mast channels. Full-free lift is available only on masts that have free lift cylinders. A free lift cylinder consists of a lift cylinder rod and assembly that is used to lift the carriage prior to the rear cylinders engaging.  This allows the carriage and forks to be lifted to a certain point prior to the inner mast rails. In many cases, you can get several feet of free lift depending on the mast design.

Full-free lift is helpful in areas where you need to lift a load, but have to be mindful of overhead obstructions.  Common areas where this is useful are for buildings with low ceiling heights and on trailers or box cars.

Original Post:  Kenny Trusnik, MArketing Systems & eCommerce Specialist, Toyota Material Handling, USA

Different types of pallet racks might offer the best solution for your operations – and Dillon Toyota Lift's Warehouse Solutions team can source whichever you need. But how to choose? Here are some basics to help:

Selective Racking – Usually single-deep, this type of racking makes any pallet in the rack system accessible without having to move another pallet.

Pallet Flow Racking – Often referred to as gravity racking, gravity allows the pallet to roll to the front of the system upon loading. When the pallet is removed from the front of the racking system, the pallets behind roll to the front.

Push Back Racking – Used for high-density storage, carts in the rack are stacked on top of each other. The first pallet is loaded from the front and sits on the top cart. When the second pallet is loaded, it pushes the top cart with the first pallet back, granting access to place the new pallet on the second cart.

Drive-In Racking –Used to store a high number of SKUs, forklifts drive into the racking system to move a pallet. This type of pallet racking system is cost-effective by maximizing storage space.

Forklift accidents can happen anywhere, but because loading docks are typically narrow and elevated, they’re one place where extra caution should be used. Common loading dock incidents include falling off the edge of the dock, and skidding or slipping due to wet or icy conditions. So how can the risk of loading dock accidents be reduced?

First and foremost, make sure the trailer is secured to the dock using a locking device, either on the trailer’s rear impact guard or rear wheel.  One common and dangerous issue that can arise when loading and unloading trailers in a loading dock, is the truck driver not realizing the forklift is still in the truck and pulling away, which causes the forklift to roll out. “Trailer Creep”, which happens when trailers gradually move away from the dock because of constant movement inside them, can also happen. The only way to prevent these two things from happening is to completely secure the trailer with a locking device on the trailer’s rear impact guard or rear wheel.

Clean off the surface of the loading dock. One common cause of accidents involving forklifts and loading docks is ice or water covering the dock. Clean the dock off before operating the forklift on it to help prevent sliding issues.

Also, remember to always maintain a safe distance from the edge of the loading dock. OSHA doesn’t recommend a specific measurement between a forklift and the edge of a loading dock, but you should implement good judgment to avoid falling off the side of the loading dock. Painting the edges of the loading dock a bright color is one thing you can do to help forklift operators stay aware of dock edges.

By doing the three things above, you’re well on your way to reducing accidents on loading docks, but keep these things in mind too:

• Anyone operating a forklift should be trained. Proper operating training is the number-one way to prevent accidents.
• Implementing a daily loading dock inspection is important to the safety of operators and truck drivers alike.
• Keep the product secure on your pallets by covering them in plastic or metal.
• Double check floors of trailers before driving on them to ensure they’re sturdy enough to handle the weight of the forklift.
• Consider creating a dock shelter to keep rain and snow off loading docks, which can cause them to be slippery.

Original Post:  Jake Stewart, Digital Copywriter, Toyota Material Handling USA

Your business is growing and you either need to expand your current warehouse or build a new warehouse to support your growth. Sounds like a good problem to have! At least, until you have to decide what type of pallet racking system you need to install. In its simplest form, a pallet racking system is a material storage system. Pallet racking helps you stay organized within your warehouse and better manage you inventory. Choosing pallet racking, however, is not as simple as selecting a pallet rack brand and installing it. There several racking types that help you meet your needs. The type of racking you choose depends on a few criteria:

• How tall the racking needs to be
• What goods will be stored
• What the floor plan will be
• What type of inventory management system makes sense for your product and operation
• What types of forklifts you currently use or forklifts you intend to switch to

Types of Pallet Racking: Selective Racking

Selective racking systems are some of the most common and widely used racking systems, mainly because they are less expensive and easier to install than other, more specialized racking systems. Selective racking is great for warehouses that store a large amount of stock keeping units (SKUs). Selective pallet racking is usually a single-deep pallet rack. This type of racking makes any given pallet in the rack system accessible without having to move another pallet.

Types of Pallet Racking: Cantilever Racking

Cantilever Racking systems are used to store items that cannot be easily stored on pallets. Warehouses that use cantilever rack, usually store longer and heavier items to be stored horizontally across multiple arms (like lumber or steel pipes). Pallet racks, on the other hand, have vertical uprights that limit the length of stored items. This is the primary difference between cantilever racking and pallet racking.

Types of Pallet Racking: Pallet Flow Racking

Pallet flow racking systems are also referred to as “gravity flow” racking systems. Pallet flow racking systems are best suited for the first-in, first-out (FIFO) inventory management methodology. When you load a pallet from the loading aisle and onto the lane rollers, gravity allows the pallet to roll to the front of the system. When the pallet is removed from the front of the racking system, the pallets behind roll to the front of the lane. Pallet flow racking allows for high-density storage while maintaining FIFO. Some pallet flow racking systems may hold up to 20 pallets deep in one lane, minimizing the number of aisles needed to store items while maintaining efficient inventory turnover.

Types of Pallet Racking: Push Back Racking

Push back racking systems is another high density storage option, with the ability to store up to six pallets deep on either side of an aisle. There are usually three carts stacked on top of each other.  The first pallet is loaded from the front in a push back racking system and sits on the top cart. When the second pallet is loaded, it pushes the top cart with the first pallet back. Push back racking gives you higher density storage than selective racking systems, while allowing you more selectivity with storing items than other types of racking, meaning you can store more SKUs.

Types of Pallet Racking: Drive-In Racking

Drive-In racking systems are great for storing large volumes of just a few SKUs and can also be configured to manage inventory with FIFO or last-in, first-out (LIFO). With drive-in racking, the forklift literally drives into the racking system to move a pallet. This type of pallet racking system is cost effective by maximizing the amount of storage space in your warehouse.

Choosing between these types of racking systems will depend on the various goals of your operation and the relevant inventory data like volume and throughput. No matter your decision, always be sure that this racking is installed safely and effectively to increase productivity.  Dillon Toyota Lift's Warehouse Solutions team is here to help from start to finish.  

Original post by:  Kenny Trusnik, Marketing Systems & eCommerce Specialist, Toyota Material Handling, USA

It’s a given – Dillon Toyota Lift has you covered when it comes to forklifts.  But did you know we also offer racking, dock equipment, cleaning equipment, scissor lifts, batteries, and attachments? That’s right – DTL is your full solutions provider for everything material handling, including warehouse design!   

Do you need to set up a new warehouse or better utilize your current space? Dillon Toyota Lift's Warehouse Solutions team can provide project design and layout, seismic engineering, permit application/approval, and more.  Not only that, we can purchase the racking and warehouse systems, and manage the installation process. Leave it to our in-house Warehouse Solutions team to figure out just what you need.

Does your warehouse or facility need a good cleaning? DTL also offers a full-line of Advance Industrial Cleaning Equipment that includes sweepers, scrubbers, sweeper-scrubbers and wet/dry vacs.  

Do you need more space in your facility? Dillon Toyota Lift also offers mezzanies.  Mezzanines can create additional space for a variey of different uses from storage to extra office space.  

As you can see, Dillon Toyota Lift has specialties that extend beyond the #1 selling forklift (Toyota).  If we can’t provide a solution, we can point you to an expert. So, the next time you need something unique for your facility or business, contact Dillon Toyota Lift!

It’s a given – Dillon Toyota Lift has you covered when it comes to material handling equipment. But did you know we also offer warehouse design and system integration?   Today's warehouse can range from simple shelving to complex systems.  Whether your business is growing or just starting, an efficient warehouse is more important than ever.

Dillon Toyota Lift Warehouse Solutions specialize in material handling equipment, warehouse design and system integration.   DTL knows that your business has specific needs and material handling is not always a one size fits all package.  We believe the key to a successful system begins with communication, planning and focusing on your needs.  Dillon Toyota Lift Warehouse Solutions offers a full range of services, including:  

Preliminary Consultation & Data Collection
• Project Design & Layout
• Equipment Purchasing
• Seismic Engineering
• Permit Application & Approval
• Project Management
• Professional in-house Installation
• Employee Training

Ready to get started?  Contact us today! 

Your business is growing and you either need to expand your current warehouse or build a new warehouse to support your growth. Sounds like a good problem to have! At least, until you have to decide what type of pallet racking system you need to install. In its simplest form, a pallet racking system is a material storage system. Pallet racking helps you stay organized within your warehouse and better manage you inventory. Choosing pallet racking, however, is not as simple as selecting a pallet rack brand and installing it. There several racking types that help you meet your needs. The type of racking you choose depends on a few criteria:

• How tall the racking needs to be
• What goods will be stored
• What the floor plan will be
• What type of inventory management system makes sense for your product and operation
• What types of forklifts you currently use or forklifts you intend to switch to

Types of Pallet Racking: Selective Racking

Selective racking systems are some of the most common and widely used racking systems, mainly because they are less expensive and easier to install than other, more specialized racking systems. Selective racking is great for warehouses that store a large amount of stock keeping units (SKUs). Selective pallet racking is usually a single-deep pallet rack. This type of racking makes any given pallet in the rack system accessible without having to move another pallet.

Types of Pallet Racking: Cantilever Racking

Cantilever Racking systems are used to store items that cannot be easily stored on pallets. Warehouses that use cantilever rack, usually store longer and heavier items to be stored horizontally across multiple arms (like lumber or steel pipes). Pallet racks, on the other hand, have vertical uprights that limit the length of stored items. This is the primary difference between cantilever racking and pallet racking.

Types of Pallet Racking: Pallet Flow Racking

Pallet flow racking systems are also referred to as “gravity flow” racking systems. Pallet flow racking systems are best suited for the first-in, first-out (FIFO) inventory management methodology. When you load a pallet from the loading aisle and onto the lane rollers, gravity allows the pallet to roll to the front of the system. When the pallet is removed from the front of the racking system, the pallets behind roll to the front of the lane. Pallet flow racking allows for high-density storage while maintaining FIFO. Some pallet flow racking systems may hold up to 20 pallets deep in one lane, minimizing the number of aisles needed to store items while maintaining efficient inventory turnover.

Types of Pallet Racking: Push Back Racking

Push back racking systems is another high density storage option, with the ability to store up to six pallets deep on either side of an aisle. There are usually three carts stacked on top of each other.  The first pallet is loaded from the front in a push back racking system and sits on the top cart. When the second pallet is loaded, it pushes the top cart with the first pallet back. Push back racking gives you higher density storage than selective racking systems, while allowing you more selectivity with storing items than other types of racking, meaning you can store more SKUs.

Types of Pallet Racking: Drive-In Racking

Drive-In racking systems are great for storing large volumes of just a few SKUs and can also be configured to manage inventory with FIFO or last-in, first-out (LIFO). With drive-in racking, the forklift literally drives into the racking system to move a pallet. This type of pallet racking system is cost effective by maximizing the amount of storage space in your warehouse.

Choosing between these types of racking systems will depend on the various goals of your operation and the relevant inventory data like volume and throughput. No matter your decision, always be sure that this racking is installed safely and effectively to increase productivity.

Written By:  Kenny Trusnik, Marketing Systems & eCommerce Specialist, Toyota Material Handling, USA