40% of all forklift accidents involve a pedestrian. Safety comes standard on all Toyota forklifts and we recommend that all operations follow safety best practices to help limit risk to operators and pedestrians in material handling settings. However, there are certain job sites in which alternative precautions for visibility make sense. Enter the Red-Zone LED Warning Light.  

Ensure pedestrians stay a safe distance away from the lift truck with the Red-Zone LED Warning Light. The Red-Zone emits a red beam on the floor to keep pedestrians away preventing foot injury or collisions from rear end swing. The Red-Zone LED Warning Light also includes mounting hardware.  Buy Now!

With a wide range of maintenance checks that need to be performed on all forklifts, it can be easy to allow some part of your equipment fall out of OSHA or ANSI compliance. One aspect of fork inspection that can sometimes slip between the cracks is ensuring that forks are maintained appropriately in compliance with ANSI 56B (updated in May 2017).

In order to complete the appropriate checks and maintain fork compliance, you’ll need to make appropriate use of a fork caliper. This device can be used in three important ways to help you measure fork deviations and get the appropriate information to make sure you’re following the ANSI standard.

Fork Inspection: Check Fork Angle

The Fork angle deviation must be within a margin of 3 degrees. That means that the angle between the blade and the shank must be between 87 and 93 degrees. To use the caliper to check this, open it and place it between the plate and shank so that all four protrusions are touching. The angle can be read using the marking on the caliper. Any fork angle that falls outside of the degree range must be tagged out until the forks are replaced.

Fork Inspection: Check Fork Hooks

The numbers on the end of the caliper indicate the forklift classes. Use the appropriate protrusion to check if the fork hooks are in compliance. Simply place the protrusion into the hook notch. If the hook hits the back of the caliper, it is out of compliance. If it does not, then the forks are fine for continued use. The above fork is in compliance.

Fork Inspection: Check Fork Blade Wear

Begin by setting the caliper by the thickness of the shank. Place the caliper onto the blade at the point of the fork that receives the most wear, which is usually at its heel, as shown. If the blade passes the inside teeth of the caliper, then the fork is out compliance and must be tagged out until forks are replaced.

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

Forklift operator safety training is pivotal for ensuring safe, efficient operations. Unfortunately, even the most effective and reliable forklift operators can still find themselves in situations that put them at risk of tipovers and injury.

To help prevent these inevitable situations, Toyota has equipped most of our forklifts since 1999 with the patented System of Active Stability (SAS.) SAS is an efficient and effective forklift system that takes over 3,000 readings per second to detect unsafe operating conditions. If a safety hazard is detected, the SAS activates one of its two main features that improve lateral and longitudinal stability of the forklift.

Active Control Rear Stabilizer System
The Active Control Rear Stabilizer System uses a patented swing lock cylinder to increase lateral stability by locking the rear steer axle. By locking this in place, the forklift’s stability footprint is converted from its usual triangle to a rectangular pattern, reducing risks of a lateral tipover.


Active Mast Function Control System
When sensing risks for a longitudinal tipover, the Active Mast Function Controller System triggers forward tilt control or rear-tilt speed control.


When activated, the forward tilt control detects the load weight and the extended mast height. It then reduces the reverse tilt speed of the mast by half of its unrestricted speed.


The rear tilt speed control similarly detects the mast height and load weight to decrease the mast’s tilt speed, reducing chances of a load spilling or a reverse tipover.Toyota’s SAS system is the first and only of its kind in the material handling industry. It has been accepted across the industry as one of the most important safety developments in material handling industry. That’s because Toyota SAS is key to protecting your most valuable assets – your operators.

Toyota SAS Protects Forklift Operators
Toyota engineers developed a dynamic forklift system for safety comprised of 10 sensors, 3 actuators, and a controller which protects the driver, load, and surrounding environment while facilitating efficient, productive material handling. System of Active Stability (SAS) works by continually monitoring the forklift’s operations and automatically taking protective action when needed.
This was all implemented on most Toyota forklifts in 1999 in order to protect operators in potentially hazardous situations. Here are some specific ways that that Toyota SAS forklift system help to protect operators.
The Active Mast Control and Swing-Lock Cylinder functionalities exist as protectants for expertly trained operators. They add an additional layer of security that can increase safety when paired with proper forklift operation.
Since transforming the safety triangle to a rectangle is not possible with a 3-wheel configuration, SAS takes a different approach to safeguarding stability of 3-wheel forklift models. Excessive speed when cornering is a leading risk factor for lateral tip-over accidents. The Speed Reduction When Cornering feature overrides manual controls by limiting the drive speed when cornering.
Some of the most potentially dangerous forklift uses occur when a load is being moved at height. The front angle control helps protect against forward tip over and losing goods off the forks, causing them to fall. The read tilt speed control reduces the risk of dropped loads occurring when loads could potentials slip over the mast.
Operator protection is our number one concern at Toyota, which is why we invest so heavily in safety features for our Toyota forklifts.

Toyota SAS Myths Debunked
The System of Active Stability (SAS), which is unique to Toyota and comes standard on most Toyota forklifts, has been created to assist in safety. And with all systems that are exclusive and top of the line, investors in such technologies legitimately ask whether it’s really necessary and consider all possible problems. But the fact is Toyota SAS offers only benefits to the safety of your operators. To offer peace of mind, we can help to debunk some myths about Toyota SAS.
Myth #1: SAS causes forklift operators to drive unsafely.
Truth: Any properly trained forklift operator is capable of operating a forklift safely. Properly trained forklift operators understand that even with SAS, it’s important to operate the forklift safely.
Myth #2: SAS must be inspected every 40 hours.
Truth: SAS actually only requires a 30-second check every 250 hours.
Myth #3: SAS causes excess downtime.
Truth: There are 200,000 forklifts with SAS today and according to studies, those units have 99.7 percent up-time.
Myth #4: There are 3,000 sensors in the SAS.
Truth: There are only 14 sensors in the SAS. Those 14 sensors automatically monitor the forklift 3,000 times per minute.
The benefit of Toyota SAS is just one reason why Toyota continues to be an industry leader in material handling safety. Need more reason to invest in Toyota SAS? There are clear financial benefits as well.
Toyota SAS Offers Positive Financial Implications
The benefits of Toyota SAS extends to the balance sheet, as the overall cost of a forklift accident far outweighs the upfront expenditure for a Toyota and the minimal cost of maintenance. How minimal is that maintenance cost? SAS requires little-to-no maintenance. In fact, of all the SAS systems on forklifts in the field, the average cost of maintenance per year is around $17.
Now, compare that to the cost of a tip over…
SAS helps prevent accidents from happening due to an unstable forklift. If it were able to prevent just one accident, it would pay for itself one-thousand times or more. That’s huge.
At $17 per year, SAS is the best (and probably most economical) decision you can make for your business. And since the forklift system is exclusive to Toyota, that’s just one more reason to make your material handling fleet a Toyota fleet.

Having a daily forklift inspection may seem like such a simple task, but operators can be tempted to skip having this daily walk around. Finding a small issue with your forklift now, can prevent a larger problem from taking place later on. This not only protects your operators, but as well as any pedestrians and product that your forklift will be around. Not to mention, it is also stated in OSHA 29 CFR 1910.178 standard language that forklifts must be inspected before being put into service at the beginning of a shift or daily where vehicles are in round-the clock use. Here are some of the best practices when performing your daily forklift inspection.

Have a checklist

Whether you’ve created the checklist, or the manufacturer has provided you a sample, having one helps ensure that your operator is looking over every part of the forklift. If you are improvising your required daily walk around, you may miss something important.

Make it a Routine

We understand things get busy and every facility gets hectic, but if you can implement an inspection at the beginning of every shift, it will eventually become a habit. Get into a routine, and stick to it. If you’re an operator, you’ll be more comfortable knowing you’re driving a forklift that is in safe, working order. If you’re a manager, you’ll have peace of mind that your operators are using forklifts that will work, maintain efficiency, and keep them safer.

If a Problem is Found, Pull the Forklift

If you do find an issue, don’t run the forklift. Tag it out of your operation immediately. Safety should always be your first priority. You may be losing some money while the forklift is down, but you also may be protecting yourselves, or your driver, from something worse. Small problems can quickly turn into bigger costs and safety concerns. And downtime can be mitigated by having a full-line forklift supplier who provides excellent and timely service.

Keep in mind, different forklifts require different inspection check lists! If you have a large fleet with many different forklifts, make sure they have their own specific inspection sheets. 

Original Post: Lucas Collom, Digital Projects Administrator, Toyota Material Handling, USA

1.  A History of Excellence and Leadership: Toyota’s forklift division began in 1956 in Japan with the introduction of the first Toyota forklift. Today, Toyota is the world leader in forklift sales.

2.  Safety Innovation: Toyota introduced the world’s first and only System of Active Stability (SAS). The system electronically monitors the forklift’s operations to help reduce the likelihood of both lateral and longitudinal tip-overs.

3.  Technical Innovation: In 2000, Toyota became the first major forklift manufacturer in the United States to offer AC technology to provide high performance and efficiency. The AC motor contains no springs, brushes, commutators or directional contractors, making is virtually maintenance free.

4.  #1 in Quality, Durability, Reliability, Value and Lowest Cost of Ownership: Toyota forklifts are ranked number one in numerous studies conducted by Peerless Research Group.

5.  More Than a Forklift Manufacturer, Toyota is a Full-Line Supplier: In addition to a full line of high-quality forklifts, Toyota offers other industrial equipment products including narrow aisle solutions, walkie stackers, automated guided vehicles (AGV’s) and tow tractors.

Click here to learn more about why you should consider choosing a Toyota forklift from Dillon Toyota Lift.

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

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

Sending operators to forklift training to improve safety and increase efficiency isn't just a good idea...it's an OSHA requirement.  In a workplace environment, most employee injuries and property damage can be attributed to a lack of, or inadequate, training. A comprehensive forklift safety training program is one of the most effective ways to combat workplace injuries.

There are specific rules set forth by The Occupational Safety & Health Administration (OSHA) concerning forklift operator training and licensing.

OSHA 29 CFR 1910.178(I) requires that employers provide forklift operators training for vehicle inspection and maintenance. Operators must be over 18 years of age and be recertified at least once every three years. 

Businesses are required to develop and enforce a written program that includes, but is not limited to:

• Forklift Operator training
• Licensure
• Review/renewal program

This is an OSHA requirement for every forklift operator within an organization. Every aspect of the forklift operation must be covered, from setting the parking brake to forklift speed.

Forklift training is available on-line, however, an operator cannot be certified to operate a forklift through an online course! OSHA certification requires:

• Formal instruction in any combination: (lectures, discussions, on-line courses, video presentations, written material).
• Demonstrations performed by a certified trainer and then exercises performed by the trainee.
• A thorough Evaluation of the forklift operator’s performance on the job.

Other OSHA Forklift Requirements:

• Vehicle Inspection and Maintenance: It is important to establish a vehicle inspection and maintenance plan for forklift operators to adhere to. While training is vital, a forklift operating at premium performance helps assure a safe work environment.
• Daily Forklift Checklist: OSHA has an approved daily checklist for all forklift operators to adhere to before they begin each shift.

Dillon Toyota Lift offers a variety of safety training classes for both operators and trainers and safety training materials.  We offer flexible class schedules and training classes available on-site at your facility or any DTL location.