Knowing when it's time to replace forklift tires is essential for safety, efficiency, and cost-effectiveness in your warehouse or industrial facility. During your pre-shift inspection, make sure to look for these warning signs that your tires may need replaced:

Tread Wear: Excessive tread wear is one of the most obvious signs that your forklift tires need replacement. When the tread depth reaches the wear limit indicated on the tire, it's time for new ones.

Flat Spots: If you notice flat spots or uneven wear patterns on the tire surface, it can affect the forklift's stability and performance. This is a clear indication that replacement is necessary.

Cracks or Cuts: Visible cracks, cuts, or gouges in the tire rubber can compromise its structural integrity and safety. Damaged tires should be replaced promptly.

Bulges or Blisters: Bulges or blisters on the tire's sidewall or tread area are signs of internal damage. These can lead to blowouts or other hazardous situations and should be addressed immediately.

Loss of Traction: Reduced traction and slipping on surfaces that were previously manageable can be a sign of tire wear.

Vibration: Excessive vibrations during forklift operation can be caused by worn tires. Vibrations can lead to operator fatigue and affect the forklift's stability.

Regular inspections of your forklift tires and keeping accurate maintenance records can help you identify these signs early and replace tires as needed, ensuring the safety of your operators and the efficiency of your material handling operations.

Our certified technicians are available to assist you with recognizing potential issues and with maintenance and repair.

Dillon Toyota Lift is also offering a special on forklift tires now through November 30^th, 2023. Save 15% on tires & additional discounts available for bulk orders! *Pneumatic tires excluded.

Being in a warehouse, and running forklifts through multiple shifts a day can be an extremely taxing job. You need to take time to charge and let them cool down, which in busy operations can be difficult. Now, with the emergence of lithium-ion batteries, opportunity charging is becoming more popular. But what is it?

What is Opportunity Charging?

Opportunity charging is available for forklifts with lithium-ion batteries and lead-acid batteries but is much better suited for LiB. With this method, the batteries can stay in the truck for multiple shifts while being charged. It also takes advantage of breaks to charge the forklift. This means, when your employees are on lunch, taking a break, or switching shifts, the forklift can be plugged in and charged. When the operator returns, the forklift will have enough juice until the next charging opportunity. While opportunity charging is still available for lead-acid batteries, it can have some negative side effects, such as shortened battery life, and increased maintenance requirements. Whereas lithium-ion batteries, it can actually extend the overall life, and there is no need for increased battery maintenance.

What type of Warehouses Utilize Opportunity Charging?

While opportunity charging is best used for multi-shift warehouses, you can schedule a warehouse consultation with your Toyota Forklift dealer to see if it would be beneficial for your business. But in a single shift cycle, you have plenty of time to allow the forklifts to charge when the shift is over. In a multi-shift cycle, you don’t have the benefit of time, so opportunity charging can be extremely helpful in reducing downtime.

Considerations for Opportunity Charging

Now that you know the basics of opportunity charging, you might be open to the idea. But before you can move any further, make sure you take these things into consideration:

• Will your operation benefit from opportunity charging?
  • As we talked about before, opportunity charging is typically for multi-shift operations. See how much time passes between each shift break and if you find that some forklifts have downtime while you wait for them to charge, opportunity charging may be beneficial.
• What kind of charging stations do you have?
  • Opportunity charging does require a specific charging station, so you won’t be able to use the same charging station as you used for your lead-acid batteries. This is an initial investment that your company will need to consider before they make a decision.
• Contact Dillon Toyota Lift if you have any doubts!
  • We can be an excellent resource if you’re thinking about changing to lithium-ion batteries and opportunity charging. We will be able to help you understand if your business needs to make a change, as well as the proper location and process for when the changes are made.

Keep in mind, opportunity charging won’t work for every operation. 

Toyota’s continued commitment to safety sets the standard in the material handling industry. At Toyota, we take safety as an enduring promise to our customers, one that we’ve delivered on time and time again, from our introduction the System of Active Stability in 1999 to our continued support of National Forklift Safety Day.  As Toyota Material Handling President and CEO and former Industrial Truck Association chairman, Brett Wood, says “If you have a safe, comfortable operator, you’ll have a productive operator.”

But maintaining the health and safety of your employees isn’t just imperative to the success of your business. It is also your legal responsibility under OSHA’s General Duty Clause. An unsafe workplace environment can have a much deeper impact than just lost time and productivity or increased cost. Working in unsuitable conditions or operating unsafe machinery can cause considerable damage or even fatal outcomes. What measures can you take to ensure the safety of your employees and maintain a culture of safety awareness for forklift equipment?

Be sure that only trained operators are using any forklifts or other equipment.

All equipment should be properly maintained and inspected regularly to confirm that it is in safe working condition.

All equipment should be used as intended.

An unsafe environment can lead to expensive costs of repairs, including incremental damage that can cost about ten times that of the cost of forklift repairs. Adding a Toyota Planned or Full Maintenance plan can help you ensure the excellent and safe working condition of your forklift and reduce these costly, incremental repairs. By making sure these precautions are in place, you will help protect your employees and your equipment. 

 

As a piece of essential warehouse equipment, forklifts are everywhere. There are currently around 1,000,000 forklifts helping businesses stay organized, and productive throughout the United States. They are one of the most powerful tools in improving efficiency. However, with great power comes great responsibility. Forklifts can be hazardous, and the cause of expensive citations, workplace accidents, injuries, and even death.

According to the Occupational Safety and Health Administration (OSHA), forklift violations are consistently one of the top 10 violations costing businesses about $135,000,000 every year. OSHA also estimates that forklifts cause of approximately 110,000 accidents annually. Of these, about 35,000 resulted in serious injuries, and about 85 accidents resulted in death.

Any workplace that uses forklifts should emphasize forklift safety. Promoting forklift safety will prevent costly violations and accidents. Here are 5 ways to optimize forklift safety:

1. Make sure all employees are educated and properly trained and certified

Studies show that proper training and education is a great deterrent of accidents. Employers should develop and implement a training program based on the general principles of safe operation, the types of forklifts used in the workplace, the potential hazards in the workplace, and the general safety requirements of the OSHA standard. According to OSHA, with these training policies, about 70% of forklift accidents could be prevented.

Additionally, operators must be properly certified per OSHA regulations. OSHA requires forklift operator to be certified in a two-phase training course: a classroom-style training and test, and a hands-on evaluation. Only trained and competent operators can be permitted to operate a forklift. You can find all the necessary information about training and certification here.

2. Understanding your forklift’s load capacity and the Stability Triangle

Many forklift accidents happen because the operators are not knowledgeable about how much their forklifts can carry. In fact, tip-overs due overloading is a leading cause of forklift accidents. So, understanding your forklift’s load capacity is extremely important.

A forklift’s load capacity is found in two places: on the data plate of the forklift, and in the operator’s manual. This capacity refers to a balanced load carried on the stated load center. It can change depending on the attachments used, the height of the lift, and the length of the load.

• • Forklift attachments are anything that is attached to the front carriage or attached to an attachment on the forklift. Generally, as you add attachments to the forklift, the load capacity decreases.
  • Lift height also affects load capacity. Forklifts with high masts will have lower capacity as the lift height increases.
  • The length of the load changes load capacity as well. The longer the length of the load is the lower the capacity.

3. Perform daily inspections and regular maintenance

Maintaining your forklift is not just a great way to extend the life of your forklift, it is also one of the best ways to ensure forklift safety. Regular maintenance safeguards your forklifts against problems that go beyond the normal wear and tear. OSHA requires daily inspections to be performed at the beginning of each shift. If a forklift is equipped with a safety device, the device must be in good working order otherwise the forklift should be tagged out of service until it can be repaired. These daily inspections also help operators identify operational issues so they can be addressed before they become bigger problems or lead to accidents. By keeping your forklift in optimal working condition, you will have a safe operating experience.

4. Be aware of your work environment

A lack of awareness in the workplace can be detrimental not only to the products you are moving but also to your employees. Many accidents occur because the operator or someone in the forklift’s vicinity is not paying attention. Practice mindfulness by paying attention, keeping an eye on where you’re going, using your alarms to alert others of your presence, ensuring your loads are balanced and within load capacity, and driving safely. These five simple actions can prevent accidents and save lives.

5. Store your forklifts properly

Another way to promote forklift safety and prevent accidents is to store your forklifts properly after use. They should be parked on a flat surface. Engage your parking brakes. Make sure your forks are flush to the ground. The forklift should be turned off, and the keys should be removed from the ignition.

Your forklift battery is the powerhouse of your electric forklift. On average, with proper care and maintenance, a forklift battery lasts about 5 to 7 years. To safely get the most out of your forklift battery, check out the 8 recommendations below.

1. Dress appropriately for handling batteries  

Because forklift batteries are made from corrosive chemicals that can burn your eyes and skin, make sure to be dressed appropriately when handling batteries. Make sure to wear safety googles, rubber gloves, steel-toed boots, and an apron. Do not wear metallic jewelry.

2. Use the right handling equipment for moving batteries.

Forklift batteries are heavy. Smaller batteries can weigh 100-200lbs, but larger ones can weigh as much as 3,000lb. So, always use the appropriate handling equipment such as a battery lifting beam when lifting or moving batteries. Also, always make sure that the battery is properly secured before lifting or moving.

3. Handle and charge batteries in a designated area.

Having a designated area for handling and charging batteries is an OSHA-recommended best practice. When you charge your forklift battery, potentially flammable gases may be emitted. Having a designated, well-ventilated area prevents gas build-up. This designated area should also have eyewash and shower stations in the event of acid splashes and exposure.

4. Perform battery inspections and maintenance.

Batteries need to be inspected as a part of your daily OSHA-required forklift inspections. When inspecting your forklift battery, be sure to check your fluid levels. Make sure that the charging cables are intact, insulated, and connected. Look for cracks in the battery casing and for crystallization and corrosion. The battery’s contact posts should be clean.

5. Charge your batteries properly.

Properly charging your forklift battery is the best way to extend the life of your battery. A battery has a limited number of charge cycles in it, usually about 1,500 charges. Take care not to opportunity charge your battery. Flooded batteries should have 8 hours of run time, 8 hours of charge time, and 8 hours of cool-down time. If your operations require opportunity charging, see your battery supplier for the appropriate battery and charger combination for this type of charging capability.

To properly charge your battery, follow the below tips:

• • Make sure that your battery and your battery charger are compatible.
  • Be sure that the charger is off before connecting or disconnecting your battery.
  • Charge your battery when it hits 20% charge remaining. Do not charge the battery before it hits this red zone.
  • Always charge your battery completely. Partially charging your battery will count against your battery’s total number of charge cycles. Never interrupt a charging flooded type battery! (Unless you have an opportunity charger and battery combination.)
  • Avoid extreme temperatures when charging your battery. Charging and operating your battery in extreme temperatures will greatly reduce your battery’s life.
  • Allow your battery to cool down after charging. If you have a flooded or wet cell battery, you can follow the battery cycle of 8 hours charging, 8 hours cooling down, and 8 hours of working.

6. Check and maintain your battery’s fluid level.

As you use and charge your forklift battery, the fluid level of your battery decreases. That is why you should check the fluid level of your battery daily. You should add deionized or distilled water to your battery about every five to ten charges. Fill the cell with just enough water to cover the battery plate, usually about ¼” over the plate. Always add this water after charging, but never before charging. Also, do not overfill your battery because the water needs room to expand when the battery is in use.

7. Equalize your battery regularly.

Flooded, or wet cell, batteries need to be equalized on a regular basis. Over time, the water and acid in your battery become stratified. When this happens, your battery will not hold a charge well. By equalizing your battery, the electrolyte concentrate is rebalanced, and any buildup of sulfate crystals on the battery plate gets removed. Be sure to use a battery charger that has an equalizing setting.

8. Clean your battery regularly.

The top of your forklift battery needs to be cleaned regularly with battery cleaner or warm water regularly. Doing so is not only good maintenance practice; it can also help you maintain your battery’s manufacturer’s warranty. Also, cleaning can help you avoid battery build-up which can lead to tray corrosion and faster self-discharge.

Taking care of your forklift battery is greatly beneficial for your forklift and for your business’s bottom line. View original post HERE

Electric forklifts can be beneficial in many different work indoor applications (and now even outdoors with Toyota’s 80-Volt Electric Pneumatic Forklift). Using electric forklifts in your warehouse is one of the most common uses of these machines and for good reason. Electric warehouse forklifts can reduce fuel costs and be charged at intervals that can maximize efficiency across shifts. Take a look at some of the following benefits electric forklifts could have in your warehouse space.

Electric Warehouse Forklift Benefits

LESS NOISE

You may not think about it, but having a quieter forklift may impact you or your operator’s ability to operate safely and effectively in certain applications. In smaller, confined spaces, with multiple forklifts running, it could get pretty loud. With electric forklifts, it lowers the noise level, allowing for easier communication, and less fatigue from your operators. Really, the only noise that electric forklifts have is the horn. In certain warehouses, this can make it easier for operators and pedestrians to hear forklift horns, co-workers, or other important workplace sounds.

LOWER EMISSIONS

When you are using a gas or LPG burning forklift, you are producing emissions that could be harmful to your associates and products if not properly addressed. Electric forklifts do not generate any CO emissions. This helps keep your employees healthy and lower the impact of emissions in your warehouse.

Certain products can also be harmed by emissions including food items, other perishables, and various consumer products. Toyota electric forklifts come in a wide variety of lifting capacities to fit many different applications. Also, fewer emissions are great for the environment!

If you are using a gas or LPG forklift in your warehouse instead of electrics, we understand there are many reasons that might have influenced that decision, and Toyota is the U.S. leader in internal combustion forklifts. However, make sure you are using proper ventilation techniques if you’re using one in your warehouse.

A WIDE RANGE OF OPTIONS

Because your warehouse needs to maximize space, it could be hard to fit a full-sized forklift down your narrow aisles. An electric warehouse forklift can help solve that issue. At Toyota, we have many different electric forklifts to fit your needs. Maybe you need to squeeze in those narrow aisles? The 3-wheel electric would be perfect. It has a tighter turn radius than most forklifts but still has the capacity to lift up to 4,000 lbs. Maybe your warehouse stacks pallets behind each other. This is where reach trucks work great. Being able to place pallets in front of each other makes sure you are maximizing your warehouse space and racking. No matter what type of warehouse blueprint you have, Toyota Material Handling has an electric forklift to fit your needs!

OPERATING COST

When it comes to the operating cost of forklifts, electric forklifts can usually be lower than that of internal combustion models. While IC models run on gas, electric forklifts run on, well, electricity! You may need to set up a charging station in your warehouse, but the cost of electricity can be significantly lower than that of fuel.

While IC models are still the most popular in the market, electric forklifts are increasing in popularity. So remember, if you are looking to increase productivity and ROI in your warehouse, take a look at all of the different electric forklift options from Toyota.

Warehouse spills should be anticipated and prevented whenever possible. But even the most careful warehouse manager or operator can have a spill happen on their watch. Specific advice about what to do in the middle of a spill will ultimately depend on what you spilled. But there are some general things to keep in mind after a spill has occurred that can help you clean up and prevent the next one.

Steps to Take After a Spill

1. Assess What Happened: Determining the cause of a spill is important to determine the cause and rectify the issue before it occurs again, but also so that you can determine what you need to take into account during clean up. What was spilled? Where was it spilled? Why was it spilled? All of these questions can help you to assess what needs to be cleaned up in the facility.
2. Think about where you forgot to clean: It’s easy to remember to clean the floor surface after a spill. But have you thought about where else you need to clean? If you spilled a liquid, this could have splashed onto warehouse racking, product, or a lift’s forks. These are definitely safety hazards that can cause slipping of materials when they’re being handled. If you spilled something that scattered, be sure to check under racks and other warehouse storage systems. Loose materials are slipping hazards for both associates and forklifts.
3. Be Proactive: I know. It’s really not helpful to say “well, in hindsight, you should have….” I can’t stand the guy who says that. That guy is a jerk. But in this case, one of the best ways to prevent the next spill is to learn from the current spill and be proactive. Make sure you have clean up stations with all the proper cleaning solutions, signage, and PPE available for associates to clean the area. Material Safety Data Sheets (MSDS) must be available and accessible for reference. If you’re working with hazardous materials, make sure you have protocols in place in case you have a spill.
4. Recertify Operators: After a near miss or accident, have operators recertify (it’s actually an OSHA requirement).This will mean that they need to train again on proper operating procedures to help prevent possible spills in the future.

Automating your material handling processes presents many challenges. How will it impact material flow? Will you need to shutdown part of your operation for the installation and for how long? What type of infrastructure will you need to install and how scalable are the solutions?

Deciding that there are processes that can be improved in your operation through automation should be completed with care and guidance, if needed. But once you’ve made that exciting decision, getting started with automation is essentially as complicated as you need it to be to improve your process goals. There are many ways you can help alleviate the burden of implementation and automate tasks with ease while also allowing for scalable solutions that are easy to manage.

Here are a few helpful tips to get you moving on your path to increased efficiency and productivity with automation:

Optimize Before Automating

Automating a bad process can further amplify inefficiencies and require adjustments down the road that are rather costly to fix. While you don’t need to eliminate 100% of your inefficiencies prior to automating, it’s a good rule of thumb to analyze your operation to help make sure the solution is scalable and sustainable long-term. Toyota dealers can help you with this process by utilizing Toyota Lean Management and expert knowledge to pinpoint and eliminate inefficiencies prior to implementing automation.

Utilize Appropriate Technologies

Some automated products require additional time for implementation as well as additional infrastructure that can be costlier and cause disruption. Products like Toyota’s Center-Controlled Rider and Core Tow Tractor Automated Forklifts utilize LIDAR-based natural features navigation that requires little to no additional infrastructure. The mapping technology used by these models also makes adding units and modifying routes simple and efficient to minimize your downtime.

Choose the Right Automation Partner

When deciding on an automation partner, consider the value and expertise that they can bring to your business. What automation technologies and services do they have to offer? Can they support my business effectively at all locations? What type of support do they provide for implementation and maintenance?

Toyota’s partnership with Bastian Solutions, a Toyota Advanced Logistics company, allows us to provide unprecedented support for your business both nationally and globally. As the leading full-line material handling solutions providers, we are your one-stop-shop for your automation needs, including sales, implementation, and service.

Comprehensive training is also provided to operators and managers to ensure a smooth transition into automation. We can even train you to make route and unit adjustments on your own to minimize your downtime as your business evolves. View original post HERE