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

Warehouse receiving areas are some of the busiest places in a supply chain. Because of the variables involved with receiving such as unknown personnel (truck drivers) in your warehouse, the irregularity of goods received, and changing storage needs after product is received, this area in any operation can be very difficult to standardize. Amidst the controlled chaos of a receiving area, open dock doors that are not actively being used to unload a truck pose particular hazards for forklift operators and pedestrians. A lack of awareness of open dock doors can lead to dangerous situations that were more than likely preventable. Remembering a few important points about dock door safety might help increase safety while also maintaining as much efficiency as possible.

Reminders for Dock Door Safety

As an Operator, You Might Easily Back Off of One if You’re Not Paying Attention.

Even if you don’t see them in front of you, open dock doors are still there. It’s a major disaster if, in the middle of operating a forklift to handle material in the receiving area, an operator backs out an open door. Remember that awareness of what is behind you is key in maintaining dock door safety. Some dock levelers can be upgraded to automatically fold up into a protective barrier to help prevent the possibility of back off.

As a Pedestrian, You Might Easily Fall Off of One if Proper Precautions Are Not Taken. 

OSHA standards require that wall opening with a drop of more than 4 feet must be chained off, roped off, or otherwise blocked off. If this precaution is not taken, distracted pedestrians might walk off open docks, potentially being harmed in the fall and being left vulnerable in a busy receiving area where trucks are moving in and out. While ropes or chains meet the OSHA requirement for block off, heavy duty safety barriers can also be purchased (many times from certified Toyota dealers).

As a Pedestrian and Operator, You Might Easily Forget that Trucks Will Eventually Fill the Door. 

Dock doors are places where product is moved in quickly. Not every worker in an environment will know exactly when a truck will arrive. When working around a dock door, you must remember that semis are going to be pulling into those spaces, and drivers won’t always have the best visibility when backing in. Therefore, it is the responsibility of forklift operators and pedestrians to stand clear when a semi is arriving.
 

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

Using forklifts effectively in any application requires assessing how they will work in concert with the other elements of your facility. From understanding your dock capabilities to making sure pallet racks and forklifts match up appropriately, a successful facility takes into account every touchpoint of forklifts in use.

An easy to overlook touchpoint that requires attention is facility flooring. Too often, operations that use forklifts experience unexpected damage to both product and equipment because floors become damaged. In this post, I’ll discuss some of the impacts of damaged floors on equipment and personnel, help identify some trouble areas on concrete floors, and discuss possible solutions to damaged flooring.

Concrete Floors and Forklift Ergonomics

The thing about forklifts? They’re aren’t equipped with the suspension system of a luxury SUV. When you roll over a bump while driving a forklift, you’re going to feel it. And while Toyota forklifts are ergonomically designed for operators’ optimal comfort, a floor that’s fallen into disrepair will place stress and strain on an operators’ body. Maintaining a floor inspection schedule is key to preventing damage. But if you’re an operator and you see or feel floor damage, make sure your report it.

Concrete Floors and Forklift or Product Damage

Most forklifts that operate indoors will have cushion tires, and cushion tires are not manufactured to withstand uneven terrain. Uneven terrain includes flooring surfaces where chunks of floor are missing or general rough patches are present. When you continually drive cushion tires on a damaged floor, you’re likely to shorten the intervals between necessary tire replacement, placing strain on the forklift and on your budget.

Damaged floors might also be hazardous for the products you’re moving. Not only will driving over damaged floors cause less than optimal work conditions for your operators, it increases the risk of product spills if items fall from pallets due to traveling over the uneven terrain. Even something as seemingly negligible as increased vibration of products on a pallet can damage certain types of materials. Making sure your floors receive optimal care helps protect your investment in the product.

An even bigger investment might be your forklifts; those capital investments need protection, too. Forklifts are designed to have a low center of gravity, so there are many points on a forklift such as under the mast and chassis where under clearance is minimal. If a clearance assessment was made prior to acquiring the forklift, this may have been done prior to any flooring damage. Should floors later become damaged, you might not have the necessary clearance, potentially increasing impacts on the forklift. Such sudden impacts caused by poor flooring conditions can also damage internal forklift components over time, potentially causing a forklift to become unstable.

One helpful preventive measure? Toyota’s T-matics solution can be installed on most Toyota equipment to monitor for impacts and assess where they occur. If there is damaged floor where impacts are occurring often, T-matics might be able to help you identify the problem.

Concrete Floors Inspection Tip: Check the Joints

Performing a regular visual inspection of your floors is highly recommended. One main problem area that requires frequent inspection are the joints between concrete slabs. Because these are inherent weak points in the floor and receive pull away pressure from the weight of forklifts, they are likely to be the first places that fall into disrepair from natural wear and tear. Replacing concrete joints when they become damaged might seem like a costly investment. However, the long-term ROI of less forklift repair and more efficient operations makes the investment worthwhile.

Concrete Floors and Friction

The condition of your concrete floors goes even beyond the damage that they undergo due to wear and tear. You must also consider how friction plays a role in several critical forklift functions. When floors are wet or slick due to spills or chemicals that are used, it reduces the friction of the tire surface with the ground. This can have a significant impact on a forklift’s ability to stop or accelerate effectively, which can be an eminent safety hazard. It is imperative that floor surfaces are cleaned properly and allowed to dry before attempting to drive over them. Ensuring that the floor is also free of debris and any obstructions will help to avoid potentially unsafe driving situations. Be sure to thoroughly read and understand your forklift’s operator manual for more information regarding proper floor conditions for your particular piece of equipment.

Whatever you plan strategically to make sure your floors stay in top condition, having an inspection plan in place is key to success. Material handling investments work hand in hand with facility investments, right from the ground up.

Original Post By:  Jake Stewart, Digital Copywriter, 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!

Loading docks are one of the busiest places in any warehouse operation. The American Supply Association reports that 25% of all industrial accidents occur at the loading dock. Many of these accidents can occur while loading and unloading a trailer. Providing and reinforcing certified, OSHA-compliant safety training to workers and forklift operators which address hazards present at your specific facility (including the loading dock) and application will enhance workplace safety for both workers and forklift operators.  Toyota recommends and encourages you to consult with a safety professional familiar with your environment and application of use to assess your forklifts, other material handling equipment, other equipment used in your operation, application and workplace and your safety rules to safely integrate forklifts into your workplace loading docks. Here are some general safety considerations that should not be overlooked when creating a culture of safety on loading docks when unloading trailers.

Common Trailer Unloading Mishaps

Clutter– Empty pallets, packing materials and other debris might be trip hazards for workers or cause slippage for your material handling equipment or become entrapped in, under, or around your material handling equipment. For pedestrians and operators alike, this is a point of concern as loading docks have a great deal of traffic including forklifts, warehouse equipment, and pedestrians.

One fundamental practice we use in Toyota facilities is that everything has a place or a home, and everything is put in its place or home.  This practice has been effective in eliminating loading dock clutter.  All employees know where “home” is for materials so tripping hazards don’t pile up. For example, Toyota facilities use receptacles for plastic wrap, and operators are required to immediately move empty pallets to proper storage locations.  Depending on your operation and workplace and material handling considerations, you and your safety consultant should work together to develop standard operating procedures based on your operational needs.

Slick Surfaces– Rain, sleet, snow and spills are some of the contributing factors that may lead to slick surfaces in or around a loading dock. This can cause a slip hazard for both pedestrians and material handling equipment unloading a trailer.

To minimize this risk, keep all surfaces on and surrounding your dock dry. Sweeping, mopping and use of floor fans or dryers can help maintain dry working surfaces. In the case of a spill, workers and operators should be trained on the proper steps to make sure that the spill is cleaned up and disposed of safety and appropriately.  If it’s a hazardous substance, you should refer to all applicable rules, regulations and laws for safely cleaning and disposing of them.  And remember, if the spill involved a forklift, OSHA requires that the operator be retrained.

Trailer Creep– Trailers can move substantially under the weight of a forklift driving back and forth between the trailer and dock. This is known as trailer creep and it’s a serious safety hazard.

Use of dock levers to bridge the gap between the trailer and loading dock, wheel chocks to prevent tractor and trailer wheel movement, and automatic trailer restraints are all ways to address this potential hazard.  Once again, workers and forklift operators should receive safety training that includes the appropriate way to secure trailers at your facility.

Premature Departure– Trucks driving away before a trailer is fully unloaded is a serious concern. To minimize the potential of this occurring, clear communication between truck drivers, forklift operators, and dock managers is needed and should be a part of your safety training.

Like mentioned above, wheel chocks and automatic trailer restraints are also couple ways to reduce the likelihood of premature departure. Other ways include a lighting system that changes colors depending on the status of the unloading process or taking the truck drivers’ keys until the trailer is fully unloaded. These practices should be considered when augmenting a culture of communication and proper safety training and practices to enhance safety on and around loading docks.

By: Kayla Lumpford-Mitchell, eCommerce Marketing Specialist, Toyota Material Handling, USA