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.

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

Building a forklift that works perfectly for every application can be challenging. After all, what works for a small mom and pop retail store may not work as well for a high-throughput forging application. Options such as lights and attachments allow you to customize each forklift to fit your needs, but did you know that adjusting forklift settings can be just as critical to optimizing performance and efficiency?

Many forklifts today come standard with pre-set performance and operational settings that can be adjusted either through a built-in multi-function display or an external device such as a laptop. Toyota’s Core Electric and 3-Wheel Electric models, for example, each have over 60 different settings that can be fine-tuned through the display. These settings are protected via passwords to prevent access to unauthorized users.

Settings on Toyota forklifts are highly adjustable as most parameters have eight or more levels of adjustment. Understanding how these settings affect forklift operation is the first step in realizing productivity and efficiency gains. Below are a few examples of settings that can be adjusted and how they can impact your operation. If you feel like you may benefit from optimizing your forklift’s parameters.

Toyota Forklift Acceleration, Speed, and Braking Adjustments

Travel/Acceleration – These speeds can be adjusted to increase productivity or slow down forklifts for when precise handling is necessary. These settings can also provide energy savings in applications where quick acceleration or faster travel speeds are not necessary.

Accelerator Pedal Response* – Adjusts sensitivity to the initial depression of the accelerator pedal. Higher settings will reduce the delay between when the pedal is depressed and when the forklift begins to accelerate.

Rollback Speed* – Trucks with the rollback feature have a momentary delay followed by a controlled descent when the accelerator pedal is released while on a grade. This setting allows the travel speed and time before rollback to be adjusted.

Over Speed Alarm – An alarm sounds on the forklift when a pre-set travel speed is exceeded.

Regenerative Braking* – Adjusts how quickly the truck slows down when the operator’s foot is taken off of the accelerator pedal. Strength of “plugging” response can also be adjusted (when travel direction is switched between forward and reverse).

Toyota Forklift Lift, Maintenance, and Power Adjustments

Hydraulic Functions – Lift, lower, tilt, and attachment speeds are all adjustable. This includes starting, inching, maximum, acceleration, and deceleration settings. These settings can also provide energy savings in applications where faster hydraulic speeds are not necessary.

Lift Interrupt Level* – Used to tune the depth of discharge of a battery before the truck reaches lift interrupt. When the battery reaches the set level, the lift function will be disallowed. This allows the forklift to be matched to the battery size and type that is installed.

Planned Maintenance Hour Meter – An alarm sounds to inform the operator when the forklift is due for planned maintenance. The maintenance period can be adjusted and the alarm can be overridden.

Engine Auto Off/Auto Power Off – Engine (IC models) or battery power (electric models) will automatically turn off during a certain period of inactivity. The amount of time before it turns off can be adjusted or the setting can be turned off entirely.

*Applies to electric forklifts only.

Original Post: Trinton Castetter, Product Marketing Specialist, TMH

When a forklift is down and in need of repair, operators and managers are tasked with ensuring, first, the safety of those in their warehouse, and, second, that no further damage to the forklift or moved product occurs. When a forklift goes down, lockout tagout procedures should be initiated to help operators address both requirements simultaneously.

What does the OSHA lockout tagout standard refer to?

The OSHA Lockout Tagout Standard for The Control of Hazardous Energy (Lockout/Tagout), Title 29 CFR, outlines the required procedures for disabling machinery to help protect operators and other associates from unexpected bursts of energy or startup while maintenance activities are being performed on a piece of equipment.

Commonly, lockout tagout procedures included attaching a locked box to the forklift and a red and white warning tag hanging from the steering wheel. The box is a lockout box that isolates the forklift power source to the forklift so it cannot be operated and the tag provides information about why this forklift is locked out from its power source. Information you might see on the tag is the last date someone was working on the forklift, who last worked on the forklift, and the type of repair that is being performed. The procedure is meant to protect both the operators of the forklifts and the technicians performing maintenance on the forklifts. It’s to your benefit to fully understand this procedure as OSHA Standard 29 CFR 1910.333 requires lockout and tagout procedures be used on all equipment that uses electric energy for industrial purposes. This standard is meant to control hazardous energy such as electrical or hydraulic energy sources in forklifts. A typical lockout tagout procedure might follow these steps.

Lockout Tagout Steps

Step 1: Detail your procedure in full, including location

Step 2: Communicate the breakdown to ALL impacted associates

Step3: Shut down your equipment following detailed shutdown procedures

Step 4: Use lockout box or other procedure to interrupt energy output

Step 5: Follow procedures to eliminate any residual energy sources

Step 6: Attempt to start the equipment to make sure it will not start

Step 7: Perform maintenance

Step 7 b: Make sure to communicate breakdown across shifts

Step 8: Employ reverse lockout tagout procedures to reintegrate equipment into operation

To protect both operators and technicians, keep in mind these three tips about your lockout tagout procedure:

Lockout Tagout Procedures: Understand that removing the key is not enough

Removing the keys from the ignition is not enough to lockout your forklift. The forklift is still connected to the power source. It does not matter whether the forklift is powered by a liquid propane gas (LPG) tank or a battery, the hazardous energy is not isolated. Because the energy source is not isolated, there is potential for an unexpected release of energy, making both operators and technicians vulnerable to an accident.

Lockout Tagout Procedures: Document, Communicate, and Train Lock Out Tag Out

Your lockout tagout procedure should be well documented. The documented process also makes it easier to communicate and train employees. If employees need clarity, the documented procedure is the first resource to turn to for answers. Once the procedure is documented, communicate the procedure and set up routine training to keep lockout tagout top-of-mind.

Lockout Tagout Procedures: Inspect and re-evaluate procedures at least once per year

The success of your lockout tagout procedure cannot truly be assessed until the procedure is implemented. It allows you to gauge if the procedure is working, where improvements can be made, and how the procedure can change or evolve to become safer.

Original Post: Kenny Trusnik, Toyota Material Handling, USA

Building a forklift that works perfectly for every application can be challenging. After all, what works for a small mom and pop retail store may not work as well for a high-throughput forging application. Options such as lights and attachments allow you to customize each forklift to fit your needs, but did you know that adjusting forklift settings can be just as critical to optimizing performance and efficiency?

Many forklifts today come standard with pre-set performance and operational settings that can be adjusted either through a built-in multi-function display or an external device such as a laptop. Toyota’s Core Electric and 3-Wheel Electric models, for example, each have over 60 different settings that can be fine-tuned through the display. These settings are protected via passwords to prevent access to unauthorized users.

Settings on Toyota forklifts are highly adjustable as most parameters have eight or more levels of adjustment. Understanding how these settings affect forklift operation is the first step in realizing productivity and efficiency gains. Below are a few examples of settings that can be adjusted and how they can impact your operation. If you feel like you may benefit from optimizing your forklift’s parameters, please reach out to your local Toyota dealer for expert support and service.

Toyota Forklift Acceleration, Speed, and Braking Adjustments

Travel/Acceleration – These speeds can be adjusted to increase productivity or slow down forklifts for when precise handling is necessary. These settings can also provide energy savings in applications where quick acceleration or faster travel speeds are not necessary.

Accelerator Pedal Response* – Adjusts sensitivity to the initial depression of the accelerator pedal. Higher settings will reduce the delay between when the pedal is depressed and when the forklift begins to accelerate.

Rollback Speed* – Trucks with the rollback feature have a momentary delay followed by a controlled descent when the accelerator pedal is released while on a grade. This setting allows the travel speed and time before rollback to be adjusted.

Over Speed Alarm – An alarm sounds on the forklift when a pre-set travel speed is exceeded.

Regenerative Braking* – Adjusts how quickly the truck slows down when the operator’s foot is taken off of the accelerator pedal. Strength of “plugging” response can also be adjusted (when travel direction is switched between forward and reverse).

Toyota Forklift Lift, Maintenance, and Power Adjustments

Hydraulic Functions – Lift, lower, tilt, and attachment speeds are all adjustable. This includes starting, inching, maximum, acceleration, and deceleration settings. These settings can also provide energy savings in applications where faster hydraulic speeds are not necessary.

Lift Interrupt Level* – Used to tune the depth of discharge of a battery before the truck reaches lift interrupt. When the battery reaches the set level, the lift function will be disallowed. This allows the forklift to be matched to the battery size and type that is installed.

Planned Maintenance Hour Meter – An alarm sounds to inform the operator when the forklift is due for planned maintenance. The maintenance period can be adjusted and the alarm can be overridden.

Engine Auto Off/Auto Power Off – Engine (IC models) or battery power (electric models) will automatically turn off during a certain period of inactivity. The amount of time before it turns off can be adjusted or the setting can be turned off entirely.

*Applies to electric forklifts only.

Original Post: ToyotaForklift.com