Developing Proper Lockout Tagout Procedures

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

What is a Site Survey, and What Can It Tell You about Your Operations?

What is a Site Survey? A site survey is when a trained warehouse consultant visits a work space to help maximize the business? work place through racking, equipment, and a multitude of other factors. Their job is to help a business work as efficiently as possible and utilize all the space a company owns. But why should you think about getting one? Below are a few reasons. Warehouse Operation Efficiency Once a warehouse consultant comes on the scene at the time and date arranged specifically for the site survey, it doesn?t take long for them to identify opportunities that can carry already profitable business even further. For example, let?s say a company is using reach trucks to grab pallets, bring the pallets down, remove the product, and then put the pallet back up onto the racking unit. In this case, an order picker may be a more optimal equipment choice to get the job done. Often times, companies have already thought of this, but their response as to why they haven?t done it yet is usually: ?We?ve always done it this way.? Those words echo through warehouses and distribution centers nationwide, and often deter operations managers from making the moves they must make in order to meet the changing demands of the modern-day distribution environment. For those companies that do embrace change, a site survey typically starts by inventorying all forklifts and determining how that equipment is being used in the facility. Warehouse Storage On the warehouse floor, a site survey can help detect storage problems (e.g., stacks of pallets that are pushed into corners using hand pallet jacks), inventory management issues, and poor use of vertical space. There are times when managers say they don?t have enough space, but only have product stacked 12 feet high in a building with 25 foot ceilings. This is an opportunity for the warehouse to grow up , instead of out. The site survey will also help determine the best equipment for this type of application, such as order pickers, reach truck, or a combination of both. All of these steps culminate into a complete warehouse optimization package designed to help operations achieve and exceed their customer service, safety, and profitability goals. By getting material handling professionals involved early in the process, these operations may be able to optimize their space and equipment in a way that they may not have been able to handle on their own. If you would like to learn more about site surveys and warehouse consultations, download our free E-book, ?Making the Case for Warehouse Consultants.? DOWNLOAD E-BOOK

Understanding Forklift Inspection Frequency

Forklift inspection is a task that helps to ensure material handling equipment is up to par with operation standards at all times. But how often should operators inspect their forklift? Here?s a handy guide on the frequency of forklift inspection: OSHA Forklift Inspection Requirements OSHA?s Powered Industrial Truck Standard 1910.178(q)(7) This standard is the one that controls all OSHA compliance on forklifts. To meet the standard, operators must inspect trucks: Daily (at the beginning of each day?s use) At the beginning of each shift in a continuous use facility This standard compels operators to ensure their equipment is in good working condition. Failure to operate at this frequency can result in fines from OSHA. Any operator who finds a problem with a forklift must tag it out. Why this forklift inspection frequency? The frequency of inspection helps to ensure the safe and efficient operation of your forklifts. By comparison, some of us are guilty of bad practices when driving our cars. We see something that will be a problem, and say to ourselves ?that will need fixing? eventually.? But there?s going to be a moment in time when that problem will manifest itself in a very real and dangerous way. And then we?re in trouble. Because forklifts are inspected daily or at the beginning of each shift, operators are able to catch potential problems early. And instead of having a major problem at the exact moment when a part or component breaks, we can perform maintenance that might prevent dangerous situations from ever happening. The frequency of forklift inspection helps to combat that procrastination when operating a forklift. Because forklifts are inspected daily or at the beginning of each shift, operators are able to catch potential problems early. And instead of having a major problem at the exact moment when a part or component breaks, we can perform maintenance that might prevent dangerous situations from ever happening. Also, by requiring the operators to check their forklift at the beginning of a shift, businesses aren?t relying on someone who is exhausted at the end of a shift to perform check list duties. Original Post: Bob Helfst, Toyota Material Handling , USA

The Benefits Of Using A Single Solutions Provider

Businesses have traditionally relied on multiple vendors for equipment , service , and consultation services to keep their operations running. This can be an appealing approach as you can pick and choose the right vendor based on their qualifications and ability to meet your needs. After all, you likely don?t buy your groceries in the same place where you dry clean your clothes, right? But what if you could? What if you didn?t have to drive to two separate buildings across town for these services? What if you had one main point of contact who could hand you your dry cleaning and the groceries you bought online at the same time? Or what if the person who fixed your cable could also fix that vacuum that hasn?t had proper suction for years? These conveniences translate well to the world of material handling. When you work with multiple vendors, it creates added work, takes more time to communicate between each vendor, and it can prevent you from getting the best solution that takes into account all aspects of your business. Think about it this way: If you have one company who quotes you a racking system, one that quotes you a forklift, and one that quotes you a conveyor, how can you be sure you are getting the optimal solution? How can you be sure your facility layout is optimized to accommodate all of these separate pieces of equipment? Will these individual pieces of equipment work together more efficiently and productively than if you had chosen one (or more) of those pieces differently? True full-line material handling solution providers: Not only give you added convenience, but they help to optimize every part of your business. They?re experts when it comes to providing integrated systems that optimize space and work flows. And they can help you leverage advanced technologies that work harmoniously together for the perfect blend of automated and manual material handling processes. When it comes to single solution providers, there is none better equipped to handle a wide range of challenges than Toyota. Toyota boasts the largest lineup of material handling solutions that are capable of handling materials at every point in the supply chain. Everything from parcels to pallets to containers can be handled by a Toyota product. Thanks to the partnership between Toyota Material Handling and Bastian Solutions, a Toyota Advanced Logistics company, Toyota dealers can also provide fully integrated systems with both automated and manual material handling equipment. Everything from conveyors to AGV s to automated storage and retrieval systems can be quoted through your Toyota dealer. And best of all, these pieces of equipment can also be serviced by the same Toyota Certified Technicians that work on your forklifts. Having these resources available combined with the knowledge of how they can be integrated together into one comprehensive solution is where the real value of a single solutions provider can be realized. You get one point of contact for support and service, AND you get a complete solution that is going to optimize all aspects of your business. It?s truly a win-win situation. If you?re interested in how these services can benefit you, reach out to your local Toyota dealer today. They probably won?t be able to handle your dry cleaning or fix your faulty vacuum, but a free site survey could put you on the right track to optimizing your business. Original Post: ToyotaForklift.com

Solutions for Operator Environmental Protection

Forklifts are no strangers to harsh environments. Rain, sleet, snow, wind, dust, dirt, and various other kinds of substances in the atmosphere can really do a number on them. Not to mention extreme temperatures and seasonal changes that can put a lot of stress and wear and tear on a forklift. The same applies to forklift operators who are subjected to these harsh elements as they try to get through the work day. So what can you do to help keep your operators comfortable, happy, and productive in these types of unpleasant conditions? Utilizing an operator cabin or overhead guard cover to provide an extra level of weather protection could be just the right solution. Polycarbonate Forklift Overhead Guard Cover One option for basic weather protection is the polycarbonate overhead guard cover. These types of covers are typically made available as a factory or field installable feature to help shield the operator compartment from rain and inclement weather. It consists of a polycarbonate (plastic) sheet that is attached to the top of the overhead guard. The method of attachment will depend upon the design. Many types come with tinted versions to help reduce glare form the sun. While attempting a DIY solution may seem like a cheap and efficient method to provide protection, such a solution may be a violation of ANSI or OSHA regulations. In most instances, using manufacturer approved parts and installation instructions is necessary to keep your forklifts compliant. Polycarbonate Forklift Cab In addition to a polycarbonate overhead guard cover, polycarbonate forklift cabs also include doors and front and back windshields to help shield operators from the elements in all directions. These designs typically use hinged doors and sometimes incorporate windows, locking doors, and windshield wipers as well. While these cabs don?t come with all the amenities of a steel cab, they provide a cost-effective alternative and many can accommodate additional features through a special design request. The polycarbonate cab option on Toyota?s Core IC Pneumatic models is also a great option if you?re in need of retrofitting an existing forklift with a cab. Steel Forklift Cab A step up from the polycarbonate cab, the steel cab incorporates steel panels into the design for greater rigidity and typically has a tighter seal for better protection from the elements. Many steel cabs, such as the one available on Toyota?s Core, Mid, and Large IC models also feature headliners, front and rear washer/wiper systems, locking doors, glass windows, a fan, and a heater/defroster. For warmer environments, air conditioning units can also be installed to help reduce the temperature in the compartment. Original Post: Trinton Castetter, Product Marketing Specialist, Toyota Material Handling

Tuning Forklifts for Optimal Performance

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

Actions Dillon Toyota Lift Is Taking Around the Coronavirus

A Letter to Our Customers About the Coronavirus At Dillon Toyota Lift, the safety and well-being of our employees and customers is always a priority. We have a team dedicated to our response to the Coronavirus/COVID-19 situation and have established a business continuity plan to ensure the continuation of our services. We are closely monitoring updates from the Center for Disease Control and the World Health Organization regarding COVID-19. We will continue to seek guidance from these agencies and public health officials on an ongoing basis. As our employees interact with customers and the general public, we have taken steps to limit exposure to the virus. We are providing our employees with communication updates on preparedness planning and to remind them to take necessary precautions to ensure the safety and health of our communities, as follows: ? Infection-control measures recommended by the CDC to reduce transmission ? Proactively monitor our employees? health risks for illness or exposure ? Encourage employees at risk or who may be symptomatic to not come to work ? Identify travel risks and limit non-essential travel ? Identify key personnel throughout key functions to continue to support our customers with products and services ? Provide flexibility in work schedules and working remotely for those areas impacted Please don?t hesitate to contact us with any concerns or additional requests that could arise from this unexpected situation. We will do our best to meet any extra needs and are willing to comply with your precautionary measures as well. We appreciate the collective efforts taken by all to ensure everyone?s well-being. Thank you, John Dillon CEO/President

Forklift Lighting Options

The material handling industry is composed of limitless application varieties. Sure, you have your general industries such as cold storage or lumber where common elements are shared from location to location, but even within these environments you have differences that need to be accounted for. This includes different floor types, ambient temperatures, racking configurations, lighting conditions, and so much more. With all of these varying conditions, how can you find a forklift that will work for all of them? The answer is: you can?t. This is why forklift options are so important and so prevalent in the material handling industry, because it gives you an opportunity to customize your forklift to fit your specific needs. If you?re in a cold storage environment, you likely need additional safeguards to protect against moisture and low ambient temperatures while a forging application is more concerned with how high ambient temperatures could damage hydraulic hoses and other components. These deltas can even be boiled down to some of the simplest accessories such as forklift lights . With so many lighting options available, how do you know what?s best for your application? The following breakdown will help explain some of the different options out there and their benefits so that you can make a more informed opinion next time you speak with your local, authorized Toyota dealer. Lighting Options Bulb Types Halogen Lights ? Halogen lights use a typical bulb with a filament that can be damaged due to vibration or shock. They also have more amp draw than LED lights, meaning your battery will be drained faster which can reduce your runtime on battery powered forklifts. Halogen lights are cheaper than LED in most cases, meaning they will cost you less money upfront. LED Lights ? LED lights are more durable than halogen due to the lack of a filament, they don?t get as hot as halogen and they don?t have as much amp draw from the battery. LED headlight lenses are also typically made out of plastic instead of glass, which is ideal for companies that work with consumable goods. LED lights are typically more expensive, but could save you money over time due to less replacement cost and lower electricity bills for battery powered products. Headlights Standard Overhead Guard Mounted Headlights ? Most forklifts with an overhead guard come standard with headlights mounted near the top of the overhead guard on the left and right overhead guard pillars. These lights can sometimes be modified or removed to be compatible with other options such as enclosed operator cabins. Inset Headlights ? Inset headlights are mounted further inward on the overhead guard and typically mounted to the top. Moving the lights inward within the confines of the overhead guard can better protect them from damage, but can also reduce the effectiveness of the lights since the mast can block some of the light being projected forward. Low Profile Headlights ? The headlights are have a narrower profile than the standard headlights, but are typically mounted in the same location. This allows them to be better protected without having to move them completely within the confines of the overhead guard. There are typically overhead guard mounted and mast mounted versions. Front Combination Lights ? Combination lights typically add additional functions to the standard overhead guard mounted headlights. This includes turn signal lights and parking/clearance lights. Rear Work Lights Rear Work Light ? Rear work lights are mounted to the rear of the overhead guard and aimed behind the forklift. These are helpful for lighting the area behind the forklift, which is typically useful when travelling in reverse. Low Profile Rear Work Light ? A narrower work light is mounted on the rear overhead guard of the forklift and is typically mounted within the confines of the overhead guard to better protect it from damage. Rear Combination Lights ? This option rovides additional indicators on the rear overhead guard of the forklift. This typically includes back-up lights, stop/tail lights, and turn signal lights. Specialty Lights Strobe Lights ? Strobe lights intermittently flash and are designed to help alert pedestrians and other operators of the forklift?s presence. They came in many different colors such as blue, red, amber, and clear and can also be mounted in different locations depending on the model. Blue Spot Lights ? Blue spot lights are usually mounted on the overhead guard of the forklift and aimed down at the ground in front of or behind the forklift. The distance the light is aimed away is up to the customer to determine based on the application. These lights are designed to help alert pedestrians and other operators of the forklift?s presence. In general, these can be more useful when entering and exiting aisles where the forklift and other lights may not be visible and where the color of the light stands out in the given environment. Also available in other configurations such as key-activated, travel direction-activated, and in different colors such as red. Red Zone Light ? These lights are mounted on the left and right side of the overhead guard and aimed at the ground by the customer, similar to the spot lights. They shine a red strip of light at the ground that is designed to alert operators and pedestrians to the forklift?s presence. In general, these can be more effective where the light stands out in the given environment. Activation Types Key On, Headlights On ? The headlights are wired to the key switch and will turn on when the key switch is turned on. This is a helpful time saver for when headlights are frequently used such as when loading and unloading trailers. Key Off, Headlights Off ? Similar to the key on lights, this option only turns off the headlights when the truck is turned off. This is helpful to reduce amp draw on the battery. Leaving the lights on for a prolonged period of time can drain the battery to the point that the forklift will not start. Key On, Key Off Lights ? This option will automatically turn on all associated lights when the key is turned and will turn them all off when the forklift is turned off. The lights associated with this option may vary, contact your local, authorized Toyota dealer for more information based on your configuration. Auto Lights Off (Oil Pressure) ? Lights are turned off on the forklift automatically when the oil pressure reaches a predetermined level after the forklift is turned off. This ensures the lights are turned off even if the key is turned on, but the engine has not been started. This list contains just a few of the options available today. Toyota is working to constantly develop new, innovative options and our team of expert engineers can even design custom solutions to work for you through our Toyota Special Design Request process. Be sure to contact your local, authorized Toyota dealer for more information regarding what is available and for helpful advice on what may be best for your specific environment. Original Post: ToyotaForklift.com