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

Toyota Forklifts are built to be reliable, but the life of all material handling equipment will eventually come to an end. As an operations manager, you’re in control of when to get new machines into your operation. And as an operator, you know when your forklift is breaking down way too often. When bigger issues arise or when several small issues are keeping your forklift out of use, you may be asking yourself “Is it worth the time and money to put into this old machine?” This question means you’re considering the economic life of your forklift. Every forklift has two lives, its useful life, and its economic life. Useful life is pretty simple. If your forklift cannot be repaired, and is no longer used productively, then it has seen the end of its useful life. Economic life is more complicated, and requires more planning for both use and material procurement. This information can help you decide if your forklift’s economic life is coming to an end.

Economic life is the time span it makes financial sense to maintain your forklift, rather than replacing it. You know your forklift has reached the end of its economic life when the cost of the repairs are more expensive than the cost of purchasing a new one. The stress of having a forklift out of service on both an operation and the people who run it should lead you to have a good understanding of a forklift’s economic life. First, make sure you are planning for the replacement of your older forklifts. On average, most forklifts will need to be replaced around 10,000 hours, but can even be around 8,000 hours or less for those in unique applications. With the help of our economic life of a forklift calculator, you can get insight into when your forklift will need to be replaced. This allows you to easily determine a budget, and make it a more positive experience for you and your company. It can also influence your decision on whether you want to lease or buy your next forklift or forklift fleet. Leasing is sometimes an option that can help you reduce diminishing returns from a forklift with an expired economic life.

If you are putting off getting a new forklift and constantly maintaining your old one, you could be losing a lot of profits while the forklift is experiencing downtime. It’s never too late to start planning to improve the efficiency of your operation, whether you’re looking to acquire a forklift soon, have just done so, or are using an old forklift that might be past its prime. 

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

Buying a forklift is not a small investment and it shouldn’t be treated as such. When pursuing the purchase of a new forklift or forklift fleet there are a wide variety of considerations to take into account. And not all of these are singularly focused on forklift specs. At Dillon Toyota Lift, we realize that the decision to invest in any piece of capital equipment takes time and consideration.

Product-based Questions to Ask When Buying a Forklift

Developing a thorough understanding of the available products, and, just as importantly, your own operation where those forklifts will be operated, is the first key in making a decision on what forklift to buy. Take time to reflect on your operation and consider how it can be optimized if you select certain types of equipment. Using the questions below is a good starting place; when ready, you can contact Dillon Toyota Lift to get inquiries more specific to your unique needs.
1.Do you need an electric or an internal combustion(IC) engine? Electric forklifts are powered by batteries. IC forklifts are powered by traditional engines that run on different types of fuel. Need help choosing?
2.Will you be driving the forklift indoors or outdoors? This will determine what type of tires you need. Cushion tires are best on concrete. Pneumatic tires are best for asphalt, hard dirt or firm gravel.
3.What is the width of your aisles? If your aisle space is narrow, you may need a 3-wheel forklift or a stand-up rider model.  A narrow aisle order picker or reach truck may also be your best solution.
4.How many hours a week will you use the forklift? Used forklifts are great if you only need them for a few hours a day. If you plan to run your forklift four or more hours a day, consider a new model.
5.How much weight are you lifting? Make sure to purchase a forklift that can handle more than your heaviest load.
6.How high do you need to lift a load? Purchase a forklift that can lift a load to your maximum height.
7.Will you be loading or unloading from trailers? If so, get a forklift specifically designed to work in tight areas. Pay particular attention to the lowered mast height of the forklift.
8.Do you handle food? If yes, you might need an electric forklift to avoid emissions.

Business-based Questions to Ask When Buying a Forklift

The forklift and operation aren’t the only thing to take into account when pursuing the right forklift purchase. Your business depends largely on you making savvy decisions that think more thoroughly about the big picture. Here are a few more questions you might seek answers to when buying a forklift.
1.Should I rent a model before I take the step toward purchasing? You wouldn’t purchase a car without a test drive, so you shouldn’t purchase a forklift without a test either. Request a demo or a short-term rental to test the forklift in your facility.
2.Should I be loyal to my brand or change brands? Maintaining a forklift fleet has its benefits when you consider that operators can move easily between vehicles, assuming they’ve been trained on each different type. But that shouldn’t keep you from making a change if your needs are changing or you need an upgrade. We’re confident you’ll find Toyota’s products to be top-of-the-line and the leader in quality, durability, and overall value. 
3.What is the lifetime value of my forklift? Make sure you’re choosing a forklift you can afford over its lifetime. Only paying attention to the upfront cost can be a big mistake.
4.Am I getting the forklift I really need? You’ll find that you can get a lot of extra accessories for your forklift. Make sure you get what you need, but don’t make something more complicated than it has to be.
5.Is now the right time to buy a forklift? There are many reasons to buy a forklift at the right time, and not all of them have to do with what’s happening at your facility. Pay close attention to market trends, developments in the supply chain, and even changes in tax benefits
6.Should I rent, lease, or buy? Buying brand new isn’t your only option and sometimes, it isn’t the best one. Consider all your options and decide which one is best for you.

If you’re in the forklift market for the first time, have returned to the market after a long absence, or just need to go back to the basics, understanding where to start in buying a new forklift can seem like a complex process. And it can be. That’s why getting organized in your pursuit of buying the best forklift is a great place to start, and Toyota can help to make sure you get the best ROI on your investment. Use this guide, which will show you what to expect, offer a few tips to help you succeed, and help you recognize a few pitfalls to avoid.

What to Expect Before you Buy a Forklift

Buying a forklift is a big investment and it can provide a large ROI for your business. But the wrong forklift can become just another cost center. The best forklift (which is always the right forklift for your unique operation) can help you save money, increase productivity, and decrease your overall downtime. Here are some things to expect as you go to buy a forklift.
•You’ll need to know your requirements. As you navigate the wide range of products available to in the material handling market, the first thing you’ll need to know is what you’re trying to accomplish. That means you’ll need to take time to audit your operation. You can use this list to help you get started. If you don’t know the answers, Dillon Toyota Lift can help you get the answers with a site survey.

•How high do you need to lift?
•Where will the forklift primarily be used – indoors or outdoors?
•How wide are the aisles and doors?
•How many hours will the forklift be in use per day?
•What kind of tires will you need?
•Are there any specific options or accessories you will need?
•Do you have properly trained operators? This is an OSHA requirement.

•You’ll need to decide if you want a new vs. used forklift. As a general rule of thumb, if you think you’ll run a forklift more than four hours a day, consider a new forklift. Factoring in maintenance costs, it will serve you better in the long run.
•You’ll need to consider the requirements of your people and your operation. Do you have an operator with a bad back? Consider the brand with the best ergonomics. Safety is key to success, so make sure you select the brand with the best standard safety features (like Toyota’s System of Active Stability).
•You’ll need to assess brands and dealers, in addition to forklifts. The thing about capital investments? You’ll have a much better ROI when you have a dedicated partner who can help you with all your material handling needs throughout your ownership, rather than someone who is just going to sell you a forklift. You may find a lesser known brand and a cheaper up-front price, but how easy will it be to get replacement parts when your forklift breaks down? And, why are they lesser known and cheaper? Visit the dealership and ask about the skill level of the technicians. Check references. You’re choosing a dealer that will be your material handling partner for years. You’ll be glad you did your homework. To help you get started, check out the Toyota 360 Support Promise.

A Few Quick Tips for getting the Best Forklift
1.Find a Trustworthy Brand
2.Think about What you Really Need (a good partner will help you figure that out)
3.Know what kind of power you need (think about best fuel type and tire options)
4.Consider the forklift operator (you might not be using it; but their comfort will matter for their productivity)
5.Know what you can afford and how to maximize ROI (let Toyota Industries Commercial Finance help)

Five Common Mistakes When Searching for the Best Forklift

There’s a great deal of information about what you should do when in your search for the best forklift for your unique operations. But have you ever wondered why somebody didn’t warn you when you were about to make a misstep you can’t get back? Here are some common mistakes many first-time forklift buyers make.
1.Buying on price alone: Don’t be tempted to buy the cheapest forklift that meets your minimum capacity requirements. There are many other important factors to consider before buying a forklift, and up front price is only one of them.
2.Not trying before you buy: Once you’ve decided the make and model of the forklift you want, rent one to try it out in your actual work conditions. Make sure your operator has input, too. They will be the one driving it all day.
3.Not buying from a dependable dealer:  Buy your forklift from a reputable dealer who can perform emergency and general maintenance when you need it. Otherwise, you risk considerable downtime if your forklift breaks down.
4.Not considering the total cost of ownership: Spending a little more up front can be an investment down the road, especially if your operations can become more efficient and productive over time.
5.Not considering a maintenance plan: Getting on a maintenance plan helps catch problems early to reduce downtime and keeps your operators safe with regular inspections. Maintenance plans can also help increase the life of a forklift.

Purchasing the right forklift for your operation requires that you take into account several factors that are unique to your situation. From determining the right rated capacity you’ll need to understanding the difference between pneumatic and cushion tires, there’s a lot to consider. And the actual physical space of your workplace can’t be forgotten. Calculating forklift minimum aisle width will help you make an informed decision about what warehouse forklifts to acquire. But how do you know how much space you’ll need to effectively navigate? You should always check your calculations with a certified Toyota dealer, but you can use this simple formula to help you get started:

Forklift Aisle Width Formula

Basic Right Angle Stack + 12 In. (Clearance) + Load Length

Basic Right Angle Stack:

This measurement is the smallest amount of space a forklift needs to be able to turn and enter a pallet. It does not include the length of the load that is picked up or any room for clearance. Basic Right Angle Stack measurements are listed in specification manuals. Toyota lists this spec for all of its models on each model’s specific product page.

Load Length:

Load lengths will vary depending on your unique circumstances, and you should always be sure to know your forklift’s rated capacity at certain load centers. But a rule of thumb that might be used as a starting point would be a standard pallet, which is 48 inches in length.

Clearance:

Calculating 12 inches of clearance will help to ensure you have enough space to turn in the aisle and help protect against potentially unsafe situations resulting from operator error.

Forklift Aisle Width Calculation Example:

Let’s say you’re considering purchasing a Toyota Core IC Cushion forklift for your warehouse and want to make sure you would be able to turn in your aisles with a standard pallet. According to the forklift specs, the model you are considering has a Basic Right Angle Stack spec of 86 inches.

86 in. (Basic Right Angle Stack) + 12 in. (Clearance) + 48 in. (Load Length) = 146 in. Minimum Aisle Width

Remember that this is just a start to your assessment practice. Always be sure to have Dillon Toyota Lift verify your results before you make a purchasing decision!

Original Post:  Jake Stewart, Digital Content 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

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 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