The Importance of Lockout Tagout Training

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The Importance of Lockout Tagout Training

Lockout tagout training is a way to protect yourself and others by ensuring that your forklift remains completely, temporarily off. In this article we will outline why lockout tagout training is important, what it is, what the Ontario regulations are, why you need training, and basic steps for lockout tagout. Lockout and tagout is more than putting a lock on a switch; it consists of a comprehensive step-by-step processes that involves communication, coordination, and training. Contact us for lockout tagout training.

lockout tagout training

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The Importance of Lockout Tagout Training

Forklifts undoubtedly break down and need service. Shutting them off is just not enough when repairs are required, because someone can just come along and hop on the truck, totally unaware of any issue. They may start the truck, begin driving and a major accident happens. Many serious accidents have happened when someone thought a machine was safely shut off.

According to OSHA(Occupational Safety and Health Act), following proper Lockout Tagout procedures prevents an estimated 120 fatalities and 50,000 injuries each year. It consistently ranks among the top of workplace violations. Many serious accidents have occurred because someone thought a machine was safely shut off and it wasn’t. Lockout tagout will protect you and others from injuries and fatalities. It’s very important to create change in a workplace. Organizations need to have long-term vision for plant safety and generate awareness for employers, supervisors and employees regarding hazardous energy control.  A positive attitude can prevent injuries, and a loss in production time can be minimized while profitability can be increased. One way to keep workers safe is through a dedication to Lockout Tagout.

Today many manufacturers are very focused on cutting costs and improving production efficiency; however there’s no need to sacrifice employee safety. Not being compliant with the safety rules will have big consequences – fines, penalties, plant shutdowns and fatalities. Simply LOTO (lockout tagout) is a safety practice that protects employees and visitors. Follow the six steps to ensure your safety:

  • Prepare
  • Control the energy source
  • Isolate the equipment
  • Attach LOTO devices
  • Control stored energy
  • Verify that there is zero energy left

Note: ONLY the authorized individual who placed the lock and tag onto the system is the one who is permitted to remove them. This procedure helps make sure the system cannot be started up without the authorized individual’s knowledge.

What is Lockout Tagout Training?

 

Lockout Tagout Training

 

Lockout tagout (LOTO) or lock and tag is a safety procedure which is used in industry to ensure that dangerous machines are properly shut off and not able to be started up again before work is started on the equipment in question. Lockout is a lock and key device which physically locks the forklift in a safe mode and tagout is a tag placed on the lock to identify the worker who placed it and may not be operated until the tagout device is removed.The worker then holds the key for the lock ensuring that only he or she can remove the lock and start the machine. In most cases, these devices will have loops or tabs which can be locked to a stationary item in a safe position. This minimizes workplace confusion; essentially, the equipment or forklift won’t operate, and everyone is kept informed as to why.

Tagout is used when lockout is required. A tag affixed to the locked device cautions that it should not be turned on.This labeling process is used to include the following information:


1.Why the lockout/tag out is required (repair, maintenance, etc.)
2.Time of application of the lock/tag
3.The name of the authorized person who attached the tag and lock to the system.

Lockout devices hold energy-isolation devices in a safe or “off” position; it’s a warning device. It provides protection by preventing machines or equipment from becoming energized that no one can remove it without a key. This prevents accidental startup of a machine while it is in a hazardous state or while a worker is in direct contact with it.

Note: ONLY the authorized individual who placed the lock and tag onto the system is the one who is permitted to remove it. This procedure helps make sure the system cannot be started up without the authorized individual’s knowledge.

What are the Ontario regulations?

 

Lockout Tagout Training

 

Lockout is defined in the Canadian standard lockout method CSA Z460-13 There is states that “Control of Hazardous Energy – deliberate or unintended release of hazardous energy carries the very real risk of serious injuries or even fatality. A business must be able to demonstrate due diligence toward prevention of electrical injuries to implement safety practices when employees work on or near hazardous energy. Lockout is recognized as the primary method, while there are several effective methods for controlling hazardous energy associated with potentially harmful equipment, machines and processes.”  This standard outlines the responsibility and minimum requirements to protect individuals from injury from the inadvertent release of hazardous energy when working with equipment and machines

CSA Z460-13, Control of hazardous energy, says that only authorized, or qualified, personnel should do energy isolation and lockout. “Authorized” persons are distinguished from “affected” persons who are those not directly involved in the work requiring energy control but who may be in the area. Employers should have written procedures specific to each machine that needs to be maintained or repaired. Procedures will identify the machine, the types of energy sources on the machine and the number and types of equipment needed to perform the lockout.

The OSHA standard for The Control of Hazardous Energy (Lockout/Tagout) (29 CFR 1910.147) for general industry, outlines specific actions and procedures for addressing and controlling hazardous energy during servicing and maintenance of machines and equipment. Regulations require employers to put safety procedures in place to protect workers by totally isolating machinery from the energy sources that drive them.

Why is it Important?

 

Lockout tagout safety

 

People are the most valuable asset you have in your company. It is important to realize that accidents can easily occur in industrial work settings if things are not properly handled and contained, and this is mostly attributed to the materials and processes that industrial plants have to deal with on a daily basis. While manufacturers today are very focused on cutting costs and improving production efficiency, there’s no need to sacrifice employee safety. The consequences of not being in compliance with safety regulations are drastic – potential fines for violating the regulations can be severe. The minimum fine is $5,000 to $70,000 if no deaths occur. Criminal charges and a fine of $250,000 to $500,000 will be issued for loss of life situations.

Preparation and practice are keys to ensuring that machines are locked out, or tagged without a hitch. Every team member should keep on their toes and remain sharp; this preparation will reduce the chances of an accident. Similar to the way in which training helps you stay prepared, it also allows you to properly test all your equipment and ensure that they are being properly maintained. If the equipment within your industrial setting is not being properly maintained, there is always the possibility that a lockout tagout procedure will not necessarily contain and isolate any hazardous energy. A lockout tagout procedure is like an “emergency and safety plan”. Essentially, industries have to understand the differences between an authorized employee and an affected employee, and then work this into their standing safety plans. The following video further highlights the importance of lockout tagout procedure.

 

 

Lockout tagout standard saves about 122 lives and prevents 28,000 lost workday injuries each year, therefore it’s likely that well over 800 lives have been saved since the standard went into effect. That’s more than 800 people who still come home to their families friends and loved ones. Unfortunate tragedies do still occur, but many of them could be prevented if the lockout standard is applied correctly.

Who needs the training?

 

Lockout Tagout Training

 

Training is an important part of industrial safety protocol, and it is one of the keys to ensuring that industrial spaces remain safe, secure, and efficient when handling their day to day activities. To ensure operators understand the importance of lock out and energy isolation procedures, you should involve workers in the process. They can see the dangers and risks involved, and understand why they have to follow the procedures. All authorized employees, affected employees who service or maintain equipment should be trained to protect them from serious injury and death caused for hazardous energy. Additionally temporary personnel as well as outside service and contractor personnel must also be trained in hazardous energy control. The OSHA standard concerning lockout tagout reads, OSHA considers these training requirements to be of critical importance in helping to ensure that the applicable provisions of the hazardous energy control procedures are known, understood,and strictly adhered to by employees. Employers are required to certify that effective training and retraining has been provided to all employees covered by the standard. The certification must contain each employee’s name and dates of training.

Each party in the workplace has a responsibility in the lockout program. In general:

Management is responsible for:

  • Drafting, periodically reviewing, and updating the written program.
  • Identifying the employees, machines, equipment, and processes included in the program.
  • Providing the necessary protective equipment, hardware and appliances.
  • Monitoring and measuring conformance with the program.

Supervisors are responsible for:

  • Distributing protective equipment, hardware, and any appliance; and ensuring its proper use by employees.
  • Ensuring that equipment-specific procedures are established for the machines, equipment and processes in their area.
  • Ensuring that only properly trained employees perform service or maintenance that require lockout.
  • Ensuring that employees under their supervision follow the established lockout procedures where required.

Employees are responsible for:

  • Assisting in the development of equipment-specific procedures.
  • Following the procedures that have been developed.
  • Reporting any problems associated with those procedures, the equipment, or the process of locking and tagging out.

We recommend that you should renew your training every 3 years. Proper and effective training can be the difference between a safe work setting and a hazardous one. Lockout Tagout protocols make it easier to implement safety measures, but these protocols are only as strong as the teams that carry them out, and this is where proper lock tagout training comes into play. It is often the case that people neglect to follow these guidelines, and in the absence of an effective training program, it may go unnoticed.

What industries is it most relevant in?

 

Lockout Tagout Training

 

Any industry or business that uses some kind of machinery or equipment requires lockout tagout procedures. Unexpected energization or startup of machines and equipment, or release of stored energy can cause injury. Any moving parts like presses, blades and propellers are a source of energy. Electrical, mechanical, hydraulic, and pneumatic are hazardous energy that can harm workers. Lockout tagout does not apply to all scenarios, but equipment that can be affected by stored energy include maintenance equipment, hoists, automotive lifts, material handling equipment, and other machinery.  Below is a few examples of some industries that are most often use lockout tagout training and procedures.

  1. Manufacturing –  Machinery and equipment used in the manufacturing process for companies such as Pepsi, Coke, and Intel are often powerful and dangerous.
  2. Government –  Areas of concern include boiler rooms, kitchens, loading docks, and rooftops; basically, any areas of the building where equipment that might have “stored energy” is found.
  3. Equipment Repair and Service – Modern machinery can store many different kinds of energy. These include electricity, hydraulic, gas, thermal, gravity, pneumatic, steam and kinetic.
  4. Wholesale & Distribution –  Because of the automation revolution, massive conveyor belt systems move products from place to place with little or no human interaction in companies such as Amazon and  Fedex.
  5. Mining – There are many energy sources in the mining industry including electricity, machinery, pressure lines and vessels, sliding/falling material and other miscellaneous sources.
  6. Utilities –  Energy generating requirements include both external power and energy to operate the plant itself such as wind turbines.
  7. Waste Management – This industry uses large trucks with powerful components such as the garbage truck and conveyor belts.
  8. Rail Transport – Trains have a lot of moving parts  such as the brake system and require loading processes which involve equipment and machinery.

How Can You Determine When a Machine Must Be Locked Out?

However, it is sometimes difficult to determine when a machine must be locked out and when servicing can be safely accomplished without lockout. The rule that OSHA states is that:

  • An employee places part of their body in harm’s way.
  • An employee performs any major servicing or maintenance work.

What are the basic steps of lockout tagout?

Think, Plan, and Check.

• If you are in charge, think through the entire procedure.
• Identify all parts of any systems that need to be shut down.
• Determine what switches, equipment and people will be involved.
• Carefully plan how restarting will take place. Communicate.
• Notify all those who need to know that a lockout tagout procedure …

Some basic steps are common to all lockout tagout procedures, though you will need to get more specific for your individual situation. An effective lockout tagout program should include the following 9 steps listed below.

 

 

Lockout/Tagout Safety

 

Wayco is located in Kitchener, Ontario and services customers from cities such as  Mississauga, Brampton, Hamilton, Milton, Kitchener, Cambridge, London, Guelph and many other local cities. Lockout is an essential safety procedure that prevents equipment, machines and processes from harming workers. Contact us today for qualified training in your workplace or onsite at WAYCO’s training facility!

 

 


Google ReviewGreat communication , fantastic teacher. A very good thorough training class. ~  jimshady007

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Forklift Training Guelph

In this article we will discuss the forklift training Guelph, courses Wayco provides for the growing Guelph region. Wayco has been keeping people safe across Ontario for 20 years. We specialize in providing training to experienced individuals or groups who wish to enhance their current skills and to those who are new and need to obtain certification for a new career. We are a reliable and reputable company that sets high standards and offers superior training. We strive every day to provide our customers with excellence. If you are interested in forklift training, let’s talk.

Forklift Training GuelphForklift Licence

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Guelph, Ontario is ranked fourth alongside Canada’s largest cities as a top place to do business and also ranked third in Canada for entrepreneurial perspective and tenth for entrepreneurial presence. Guelph is a prosperous innovative business community with business ownership growth that reflects new future business growth. The Winter 2018 Outlook report states that Guelph’s economy has performed strongly in recent years and is expected to continue to grow above the provincial pace for both 2018 and 2019. This is proof that Guelph is a great place for businesses looking to open or expand in Ontario and people are taking notice. 

Forklift Training Guelph

“This independent ranking confirms what those of us in Guelph have known for a long time – this city is a great place to start and grow a business,” said Mayor Cam Guthrie. “We have it all – location, skilled talent, affordability, and excellent business support networks. I often hear from local entrepreneurs that there truly is something special about Guelph.”

Guelph is proud of its diverse and stable economy. The Guelph area is attractive not only to Advanced Manufacturing companies, but also to Agri-food and Innovation firms, Environmental Management and Technology companies and Tourism Operators. It is these five facets of the local economy that have been identified in Guelph’s Economic Development Strategy as growth industries on which to focus economic development activities.  In Guelph-Wellington, there are more than 90 companies employing approximately 6,500 people in this sector. This includes:

  • government                                                                                       
  • education
  • biotechnology
  • agri-food technology
  • agricultural supply
  • equipment

  • food processing                                                                             
  • associations
  • research
  • marketing
  • other services

Key Aspects of Training

Forklift Training Guelph

Whether you need  forklift training, a forklift, or to speak to a service advisor, the services we offer will help your company on a road to success! As business develops in the town of Guelph it is necessary for our business to provide forklifts, material handling equipment, and forklift training for their facilities. It is important to provide proper training to all employees who operate forklifts, because a forklift is a powerful tool. It allows the movement and storage of product and materials efficiently and safely, however, accidents could nevertheless occur when operating a forklift. It has been found that most of the forklift accidents occur as a result of driver error. Having properly certified and trained operators on-board becomes mandatory for the business owners. Like any vehicle, there are rules and regulations that come with operating a forklift. Below are key forklift training points:

1.Safety

Forklift Training Guelph

One of the most important issues that must be addressed is workplace safety training for forklift operators. OSHA (Occupational Safety and Health Act) statistics indicate that there are roughly 85 forklift fatalities and 34,900 serious injuries each year, with 42 percent of the forklift fatalities from the operator’s being crushed by a tipping vehicle. Safety begins with proper forklift training. Because of this, OSHA requires training programs to combine formal instruction, such as lectures and written material, with practical training and a workplace performance evaluation. Forklift training reduces workplace injuries, deaths and raises awareness for hazards to the worker and others.

Not only is forklift safety training for the forklift operator but also for individuals who will work in the same area as those forklifts. Both need to know safety procedures to avoid causing or being involved in an accident. One of the major causes of work related accidents happens when a load falls onto another worker. If both the driver and the worker had been trained to clear the area, then the injury would not have occurred. Wayco’s number one priority is to ensure a safer workplace and provide your company with due diligence in your safety procedures.The combination of forklifts and workers on foot is a deadly one—usually for the worker on foot.

Business owners that use forklifts also play a big role in safety. A poor workplace design with narrow aisles, improper stocking methods, high foot traffic, excessive noise and too heavy of loads can affect the safety of your workers and contribute to the hazardous use of the forklift. Creating a workplace that is well-organized, safe and fully-functional will ensure that employees can complete their roles correctly and safely. 

Spend a little extra time on practicing safety measures around forklifts to help keep employees safe and business functioning at its optimal level!

2.Know the Machinery – and the Rules

know your forklift

Forklift technology has advanced a lot and knowing one forklift does not mean the rest are all the same. Having a clear understanding of the forklift’s load capacity is crucial. Workers with an inadequate knowledge of a forklift’s load capacity are placing themselves and those around them at serious risk. As more forklift options and attachments become available, it increases the risk of not using your forklift properly and causes accidents and injury. Understanding and knowing your forklift will increase the level of safety within your workplace. Different brands or models function differently.  Components such as pedals, switches, and steering can vary from one type of forklift to the next. In addition, the workplace conditions like rough surfaces, obstructions and closed environments can present hazardous conditions that make it critical for operators to get proper safety training. Businesses should create a forklift safety program by training their employees to have a clear understanding about their machine and the proper process and procedure for operating it. If you are struggling to know your forklift truck, please give us a call on 519-748-5440 for an informal chat with one of our friendly experts.

 Here are few tips how to get to know your machine:

  • always read the capacity plate on your machine 
  • identify any attachments and the down-rated capacity
  • be aware of your forklift and the loads you are handling; know your limits
  • different weight, size and height will affect how high or low you can lift your load
  • the higher you lift your load in the air, the farther the capacity of your forklift to fall
  • various attachments will lower your total capacity allowed

Your employees still have to deal with many risks even if you run the safest warehouse in the world. Risks could be related to equipment failures due to lack of maintenance. You should always listen to the manufacturer’s service guidelines to prevent unfortunate accidents. Here at Wayco we offer a pre-operational checklist which needs to be done prior to every shift for extra safety. In addition, a record of the forklift inspection must be kept on file to stay compliant with CSA B335-04 Section 6.8. Compliance with this by-law is required in order to renew your forklift certification every 3 years, but it may be a good option to refresh your operators sooner. Operators tend to get a little lackadaisical over time and accidents therefore tend to happen more often. 

3. Awareness

Forklift Pedestrian Training

Don’t Be Distracted: When you’re distracted you’re not paying full attention to your task and when the task is operating heavy machinery; distraction can be fatal.  It takes less than a second for an accident to happen.  If you are operating a forklift it is imperative that you avoid distractions. That means not looking at paperwork, daydreaming about what you are going to do after work, using your cell phone, or being focused on what your co-workers are looking at behind you.  Keep your focus.

Watch Out for Pedestrians: A forklift operator is responsible for operating in a safe manner; this includes avoiding all pedestrians in the work area. Pedestrians use the same roadway and you will learn at our forklift training course that pedestrians may not always be watching out for your forklift. Pedestrians may not understand that forklifts have rear steering and their visibility is restricted. Workplace safety always requires some thinking ahead; one has to imagine all of the “What ifs?”

Purchase Safety Products: For companies that care about their employees and are passionate about providing a safe workplace, Wayco has safety products such as warning lights, alarms,mirrors, back up handles, and more. The best effective traffic management is to make guarded pedestrian zones to reduce forklift accidents between forklift and pedestrians. Our comprehensive line of products developed and manufactured to deliver the highest standards of safety and protection. It is also important to receive basic awareness training to non-operators such as visitors, office staff or sales people who may venture into the warehouse or yard.

Let’s look at ways facilities can improve safety for pedestrians around forklifts:

  • wear bright clothes
  • provide safety training for both operators and pedestrians
  • utilize sensor mirrors, warning spot lights, and horns 
  • light up and keep aisles clear
  • create a safe walkway for pedestrians
  • check your warehouse for overall safety

Pedestrian safety is just as important a operator safety

 

Why Wayco Provides the Best Training

Forklift Training

 

Training and pedestrian safety around forklift operators should be a three-tiered approach. First for management, which is responsible for the larger picture of training, plant design, staff, and safety equipment. Second for the forklift operator who may encounter pedestrians, and finally training for pedestrians. At Wayco, we strive continuously to improve and train our operators and pedestrians on the newest processes and procedures. Many people and businesses are still unaware or turn a blind eye to this growing issue, and both employees and employers must take responsibility to make workplaces safer.

Forklift operator and pedestrian evaluation is a key aspect of our training here at Wayco. Our qualified instructors training policy determines if the operator has fulfilled the requirements to ensure compliance with all the safety requirements and is competent to operate a forklift.  OSHA standards does not mention how an operator gets assessed, so our excellent instructors at Wayco have established their own assessment to make sure that we comply with OSHA policy. This means we need to determine the areas where operators  are lacking skill and we need to find where they frequently commit mistakes and errors to make them a more competent operator, one who is fully aware of pedestrians. Here are a few key points that our experienced trainer  use to evaluate the operator above the standard requirements:

Forklift Training

Operator Behavior – Operator behavior is important when driving forklift trucks in the workplace. An unruly operator can influence other workers. If one operator is a bad apple; it can spoil the whole bunch as well. Their bad habits may rub off on others.

SafetyTraining at your facility, our qualified instructor is to give you clear advice on your workplace safety design. Our qualified trainers are passionate and committed to educating forklift operators in the correct and safe driving practices. They will also ensure that driver have the knowledge and understanding of how important it is to work safely each day in order to go home to their families.

Forklift Pre-Use Inspection – Our trainer will make sure you follow many aspects of forklift operation such as doing a daily checklist, recording the findings, reporting the findings to your superior, and even troubleshooting any lift truck problems. A good operator will look for possible defects and damage prior to operation.

Loading Material –  Our qualified trainer will teach you about the standard terms such as center of gravity, weight, balance, stability triangle, but will also go above the standards. Most operators do not know that when loading, they need to make sure that nobody is near the load. Many people do not realize the danger this entails. Toppling down of the load could happen, crushing someone near the load.

When Traveling – A good operator observes traffic and pedestrian rules. Warnings signs are a great tool to different key areas in the workplace to follow by all. 

 

We believe safety comes first and very much look forward to keep your visitors, employees and operators safe around your forklifts

Why Businesses Need to Train Their Employees

Forklift Training

For many employees the workplace has become a second home, due to the amount of time people spend at work. Their safety is important and employers and employees alike, should take safety seriously. Today companies have become very conscious of liability issues, fines, insurance premiums soaring, workers compensation claims, legal fees and ministry of labour enforcing its guidelines. If workers and not taught the right way of operating forklifts someone can lose their life. Proper safety makes a big difference for both the employer and the employee, because they both win. The positive benefit for the employer is a rise in productivity, fewer staff absences, less staff turnover and an improved quality of work. On the other hand employees will appreciate their safe work environment, they will become more engaged and actively contribute to the team. Human life is priceless. Forklift Safety needs to be an important priority at a workplace and Wayco can help make this happen.

OSHA statistics indicate that there are roughly 85 forklift fatalities and 34,900 serious injuries each year, with 42 percent of the forklift fatalities coming from the operator being crushed by a tipping vehicle. Safety begins with proper forklift training. OSHA requires training programs to combine formal instruction, such as lectures and written material, with practical training and a workplace performance evaluation.Forklift training reduces workplace injuries, deaths and raises awareness for hazards to the worker and others.

OSHA spells out the OSHA forklift certification requirements for employee forklift training in 1910.178(l) in the standard,  OHSA R.R.O. 1990, Reg 851. This standard requires employers to develop and implement a forklift operator training program. OSHA states that no worker shall operate a lifting device, mobile equipment, vehicle or powered machine, tool, or equipment, unless he or she is competent to do so.

OSHA requires that the forklift training program be based on:

  • General principles of safe forklift operation
  • The type of vehicles being used (the training requirements are actually for “powered industrial trucks” which includes forklifts but also other types of vehicles)
  • Hazards created by use of the forklift in the workplace
  • The general safety requirements of the OSHA powered industrial truck/forklift standard

It’s the right thing to do. Employers want to send their workers home in the same condition they came in. 

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Operating a forklift requires training and certification to ensure safety in the workplace and helps the employer comply with the law. Working safely should always be a top priority. If you are looking for expert forklift training, contact the professionals at Wayco.


Google Review ~Exceptional quality and service. Left the training class with more than I expected. Looking forward to being a repeat customer. ~ Kevin Brown

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Forklift Battery not Holding a Charge – What To Do

Did you know that a forklift battery is like rechargeable battery; it has a finite lifespan! Chances are your battery is going to give you problems at some point in time.Your battery lifespan depends on you and your application. The frequency and amount of use in which the battery has been charged will impact the lifespan and will help you get the most out of your investment. There are many ways a battery can fail, that can be catastrophic or unrecoverable. If your forklift battery is no longer holding charge, Get in Touch with Wayco. We provide a forklift BATTERY CARE program.

Forklift Battery

 

Battery not holding Charge? Contact Us

Forklift batteries are much the same as the lead acid batteries seen in cars, although forklift batteries are a lot heavier, larger and more difficult to repair or refurbish. Forklift batteries are deep-cycle batteries and for this reason they can be discharged to lower levels without causing damage. There are a number of steps that are very important to get the most life out of your battery, like cleaning, replacing fluids and removing sulfation. These can be done by the worker but refurbishing the battery is best left for a professional who has experience.

Common Problems Associated with a Forklift Battery

 Forklift batteries are very expensive and are often replaced far too soon because of improper care and neglect. Below is a list of common problems associated with forklift batteries that occur over time.

1. Short Circuit

Short Circuit Forklift Battery

A common type of short circuit occurs when the positive and negative terminals of a battery are connected with a low-resistance conductor, like a wire. With a low resistance in the connection, a high current will flow, causing the delivery of a large amount of energy in a short period of time. A “shorted” lead acid battery has the capability of delivering an extremely high current, 100 to 1000 times the typical discharge current used in most applications.The following are signs that your battery has a short circuit.

  • Very low cell voltage and specific gravity during recharging and discharging
  • Low gassing while charging
  • Extreme rise of electrolyte temperature during charging phase
  • Fast drop of gravity after charging

2. Sulfation

Sulfated Forklift Battery

Sulfation, a build-up of lead sulfate crystals, is the number one cause of early failures of lead-acid, sealed AGM or flooded (wet cell-filler caps) batteries.Sulfation is the accumulation of a crystalline form of lead sulfate on the plates of lead–acid storage batteries. A sulfated battery can lead to loss of cranking power or longer charging timesSulfation can be avoided if the battery is fully recharged immediately after a discharge cycle. The lead sulfate crystals are broken down (more or less successfully) in the charge cycle. Sometimes some crystals remain, or sometimes a battery is left partially discharged where the crystals of lead sulfate harden, and reduce the capacity of the battery to be charged. This is what desulfation is about.

  • While charging, the voltage and electrolyte temperature are much higher than the standard
  • Gassing is accelerated from charging and the gravity does not rise to normal
  • Voltage drops quickly while discharging
  • In some extreme cases, plates may become whitened 

3. Excessive Self Discharging

Forklift Battery Self Discharge

Selfdischarge is a phenomenon in batteries in which internal chemical reactions reduce the stored charge of the forklift battery without any connection between the electrodes. Selfdischarge decreases the shelf life of batteries and causes them to initially have less than a full charge when actually put to use. Self discharge is caused from improper handling. Self discharge can be thought of as energy leaking from your battery which leaks about 5% of capacity per month. At higher temperatures, the rate typically doubles, so store batteries cool when possible. Remember to always wear PPE (Personal Protective Equipment) when working on batteries.

  • Quick drop in gravity after charging
  • Charging capacity of battery significantly reduced

Important Forklift Battery Facts

An important part of keeping your warehouse operations running smoothly is proper maintenance of your forklift batteries. When a lift truck battery is down, that usually means one of your forklifts is down and you are losing productivity. First here are some facts about forklift batteries:

  • A maintained, fully charged battery will provide about six hours of use, equal to an eight-hour shift with breaks included.
  • Batteries have a lifespan of approximately 1,500 cycles lasting up to 5 years. Each charge takes a cycle out of a battery.
  • Mismatched batteries and chargers can cause major damage to the battery and the forklift.
  • Batteries must have adequate water. Typically, they need water added after five to ten charges, and only after they have been fully charged, to prevent a boil over.
  • “Remember, the battery is the fuel tank of the forklift. Look after it and it will look after you.” 

Proper Battery Care

This video shares some tips on how to get the most life out of your battery and the do’s and don’ts when handling your battery and charger. 

Battery maintenance is an extremely forgotten yet important factor; as knowing a little about forklift maintenance will go a long way. Proper battery care and watering can help extend the life of your industrial battery.  Everyday large, heavy and expensive batteries power electric forklifts and inevitably need to be re-charged. Waiting too long or making the wrong connection can cost your organization time and money. Let Wayco keep track of your maintenance so it is done on time. To get the most out of your investment, machine operators should know and practice the proper care and maintenance of forklift batteries. Here are seven simple tips for proper battery maintenance:

  1. Keep the battery dry, clean, and free from corrosion
  2. Check that the battery charger cables are not damaged or showing heat damage.
  3. Keep flames and metal away from battery top
  4. Keep vent caps tightly in place
  5. Maintain proper water level (about one half inch below the battery cap opening)
  6. Add water only after the charge cycle. Add approved water only— never add acid
  7. Set up a watering schedule either weekly or bi-monthly to ensure proper water levels
  8. Avoid charging during break times and lunch breaks because each time you connect the battery to a charger, it uses one of its life cycles
  9. Inspect for any defects or malfunctions, and have your battery service provider repair them as needed
  10.  Wash and service your battery semi-annually to help control acid and corrosion

Remember check fluid level approximately every five charge cycles, be sure to check the forklift battery fluid levels by opening up the battery.

Charging and Recharging

Forklift battery charging

An electric forklift is designed to operate for one shift and then be charged on the next shift, overnight or if it is discharged more than 30%. It is up to the user to ensure that proper charging occurs so the battery performs as it was designed to. Charging an electric forklift battery is not complicated; it just requires safety precautions and a consistent, orderly process. Properly charging a battery is all about doing it at the right time and for the right amount of time. Use these tips when charging your forklift battery:

  1. Have a specific designated area for battery charging. Always charge a battery in a well ventilated area
  2. Keeping a battery water log will help support a warranty claim.
  3. Battery should be at 80% depth of discharge before charging; charging prior to the 80% can reduce battery life
  4. If the battery overflows, rinse overflow will help prevent corrosion
  5. Ensure the charger matches the voltage and amperage of the battery.
  6. Avoid overcharging the battery which can reduce the battery life
  7. Charge in proper temperature, extreme cold and heat can reduce service life
  8. After charging cycle add water if needed. Use distilled or pure water to bring the electrolytes to the proper level. Equalize batteries regularly.
  9. Never interrupt a charge cycle if it is unnecessary. It is suggested that once a charge has started, it should be allowed to finish. 
  10. Ensure the charger is turned off before connecting or disconnecting the battery.

Remember, a discharged battery that sits for extended periods will promote hard sulfation and reduce run time and life of the battery. 

FAQ – People Also Ask

What does it mean to equalize a battery? An equalizing charge is nothing more than a deliberate overcharge to remove sulfate crystals that build up on the plates over time. Left unchecked, sulfation can reduce the overall capacity of the battery and render the battery unserviceable in extreme cases.

What does equalizing a battery do? Equalizing is an overcharge performed on flooded lead acid batteries after they have been fully charged. It reverses the buildup of negative chemical effects like stratification, a condition where acid concentration is greater at the bottom of the battery than at the top.
 
Do you charge a battery after adding water?  The best time to water your batteries is always at the end of the charge cycle. However, if the electrolyte level is extremely low or the plates are exposed to air, add some water to cover the plates before starting the charge cycle
 
Can you put tap water in a battery? Add distilled water to any cells in which the level of electrolyte isn’t touching the bottom of the fill port. Use only distilled water. The minerals in tap water will eventually reduce a battery’s capacity. If your battery is one of the so-called low-maintenance varieties, you may not see any filler caps
 
Why does the battery need to be recharged in a well ventilated area? Because batteries release oxygen and hydrogen gases when they are charging, the areas should be wellventilated with a fume hood or an exhaust fan to prevent explosions due to build-up of those gases. Using the proper tools and procedures, personnel can ensure the battery is stable during movement and doesn’t fall.
 
How many volts are in a forklift battery? The forklift battery may require ten times more current output (measured in amperes) than the golf cart battery charger can provide. Voltages of 12, 2436, and 48 volts became convenient standards as industrial electric vehicles evolved
 

In order to extend their lifespan, forklift batteries must receive the right care, at the right time. If you follow a few simple steps, you can get the most from your batteries for years to come and prevent your battery from not holding a charge.

There are three most important things to insure your battery life!

  1. Keep the battery charged
  2. Keep the battery watered
  3. Keep the battery cool

Put these simple measures in place to keep your battery healthy for longer. We hope you have grasped the benefits and basics of forklift battery maintenance. If you have any other questions on Wayco’s BATTERY Care program, please feel free to Ask Us anything related to forklift battery maintenance. 

 

Google Review ~Great communication , fantastic teacher. A very good thorough training class. ~ jimshady007

 

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Electric Pallet Jack – Get One Today

Electric Pallet Truck

If your company does dock work, delivery service, stock replenishment or heavy manufacturing,an electric pallet jack is designed to suit light to medium duty load handling and warehousing applications and it has a smaller price tag when compared to a sit-down forklift. If you are looking to purchase an electric pallet jack, contact us today; we deliver in design, customer service and value with every model we see and you will find that they are built for years of trouble free service.

Click here to discuss your pallet jack options

Electric Pallet Jacks: What is an electric pallet jack?

An electric pallet jack is a type of equipment used for low-level lifting and moving pallets; they are also called electric pallet trucks.The forks  on an electric pallet jack are separated vertically from the front wheels as the hydraulic jack is raised. Power pallet jacks are also known as electric walk behind pallet trucks. The single or double pallet jacks are used to help lift, move, and stack loads that are too heavy to lift manually and transfer from one location to another location.

An Electric Pallet Jack is smaller than a reach truck. It is commonly used in warehouses to make pulling product through the warehouse more efficient, convenient and with lower maintenance costs. It is ideal for production lines or any industrial material handling applications and is able to suit every intensive or light operation, performance and driver comfort. It is electric powered making it friendlier to the environment and ideal for warehouse applications. 

The following video shows Starke electric pallet jacks PT30-45MXA offers everything you could want in a light to medium duty electric pallet jack.

You’ll want to choose the pallet stacker lift that fits in best with your routine and warehouse set-up. When deciding this, the most important questions you have to ask yourself are how much weight will you be lifting and how high? Typically the maximum lift height is 12’ or lower and the maximum weight it can handle is up to 3500 lbs. If you require more lift height or weight than this, you should consider purchasing a forklift instead.

No more Pumping, Pushing or Pulling! Discover our full range of Starke electric pallet Jack Trucks.

How To Get An Electric Pallet Jack?

In case you are looking for a electric pallet jack for your warehouse or loading dock, Wayco Multi-Lift is the right dealer to fulfill your requirements. We carry a wide variety of electric pallet jacks. We will help you find the right one! We carry a wide range of Starke electric pallets with many options, allowing you to do more in less time with increased productivity.

When choosing a pallet truck you should consider the different power sources available. The best option, however, would be the electric powered pallet jacks as these give you sufficient power for most operations; and they are also safe to use.

electric pallet truck

Buying the electric power pallet jack means you will be getting:

  • Quality equipment that doesn’t slow down productivity
  • Optimal balance between performance, durability and cost to provide superior value
  • A highly maneuverable way to pull material through your warehouse
  • A piece of equipment designed for optimized visibility, maximum performance, and ease of service

Stärke means strength and that perfectly describes how they perform in design, customer service, and value. It describes their commitment to worker safety and to their products themselves. You will see for yourself once you purchase a piece of Starke equipment. 

What Industries Use Them the Most?

If your company’s processes involve running a warehouse based business or any kind of storage facility, then you probably own or need to own an electric pallet jack or two.  Electric pallet trucks are one of the most versatile material moving equipment in the industryBigger facilities have both the manual and electric models, mainly used for less-strenuous tasks that do not require the use of a forklift truck. Because of an electric pallet jack’s size and easy maneuverability it allows warehouse workers to transport loads quickly from one place to another. They are Ideal for small businesses such as retail stores, wholesale delivery and food processing applications.  Electric pallet jacks are often used to transport small pallets of products to delivery trucks; from storage facilities; or from warehouses to main retail floors. Small business owners and employees also use them to transport boxes, displays, filing cabinets and furniture; making electric pallet jacks extremely versatile. They are designed to be used on small delivery trucks. Their self propelled movement adds an ease of transport as well as navigation in tight and congested areas. The electric pallet truck is a handy, multi-use solution for nearly any application.

Electric Pallet Jack

What are the Benefits of Using an Electric Pallet Jack?

One of the main benefits of an electric pallet jack is their ability to cover huge distances in a short period of time at greater speeds than a manual pallet jack. When you need to haul product across the warehouse, motorization allows the operator to ride on the jack while transporting loads quickly. Employee productivity is also increased because the electric pallet truck. Other benefits include:

  • Safety – Operating a manual pallet jack does not have to be a risky procedure with proper training, anyone, no matter their physical strength or agility, can operate electric pallet jacks. However, the supportive power of an electric pallet jack can reduce strain and make operating it easier overall, which in turn helps make it a safe option for materials handling. An unobstructed view for operators gives good visibility to see what’s in front of you which significantly reduces accidents.
  • Efficiency – An electric pallet jack has the ability to cover huge distances in a short period of time at greater speeds than a manual pallet jack. When you need to haul product across the warehouse, motorization allows the operator to ride on the jack while transporting loads quickly. Electric pallet jacks can get the job done in a shorter amount of time, which in turn can lower your warehouse’s overall operating costs.
  • Eco-friendliness –  Environmentally-friendly trucks have become a popular trend. As green technology is integrated more and more into industrial and material handling enterprises, new methods of developing environmentally friendly goods and products have come to the forefront. The same is true with electric pallet trucks. Unlike certain types of fuel, electric power is a clean energy source that doesn’t produce harmful fumes and runs more quietly. That means the operator is able to ride effectively through the warehouse.

Fast And Powerful, But Safe And Easy-To-Use.

Starke Electric Pallets go green

Starke prides itself on collaborating with world leaders in automotive technology to establish and offer a dynamic line of eco-friendly forklifts and material handling appliances. STARKE forklifts offer the most current machines built on economic and ecologic technologies. Their features include energy saving and reduce component wear as compared to other competing vendors. STARKE is committed and dedicated to improving forklift solutions and reducing energy consumption. In addition, Starke offers EPA approved LPG and Diesel engines manufactured by proven companies.

How To Operate Them 

If your warehouse staff aren’t well versed in how to operate manual and electric pallet jacks safely, it could ultimately end up costing you—in more ways than one! You are likely to damage the property or cause injury to yourself or others, if you don’t follow the operation instructions and get proper pallet jack certificationFollow the steps below to ensure that you’re using an electric pallet jack safely to move pallets and loads across your warehouse or plant floor.

  1. After charging unplug the electric power pallet truck from its charger.
  2. Using the release handle lower the forks to the ground.
  3. Using the control handle maneuver the pallet jack (refer to the owner manual) by pushing the forward button to move forward or go backwards; press reverse.
  4. Line up the forks of the electric pallet truck with the pallet.
  5. In forward position move forward to slide forks into the pallet opening.
  6. Using the controls, lift the load off the ground.
  7. In the forward position use the handle to accelerate and direct the pallet jack to the location where you want to unload.
  8. Arriving to the spot where you want to unload, come to a complete stop before lowering the forks.
  9. Lower the forks to the ground all the way.
  10. Again using the control handle in the backward position remove the forks from the opening.

Electric Pallet Truck Operation

Now, you’re ready to pick up the next load! Once you know the proper steps, operating an electric or manual pallet jack is so easy a child could do it! Remember operator training and certification is still required to operate an electric pallet jack. There are many different types of pallet jacks and you must be familiar with all controls and understand the proper use of attachments.

When you are finished with the electric pallet jack, maneuver it back to the charging station and plug it in so that it is powered and ready for the next use.

What Training is Required

Electric power pallet jacks, also known as a low lift walkie, walkie-rider, or a high lift walkie stacker, may look simple in appearance – no cab, no mast, just a simple tiller arm, but they can be dangerous because the machine can cause injuries or damage property. Therefore, you still require a training certification to prevent accidents. Keep your employees, trucks, and work spaces safe with electric pallet truck training with Wayco. Our course is designed to provide pallet truck operators with the knowledge required to competently and safely operate the equipment.

The greatest part of our training is the way it shows you the danger of what could happen if it is not used properly. Our training also includes:

  • Health & Safety Standards
  • Do’s and Don’ts
  • Preventative Maintenance
  • Proper Procedures for Safe Operation
  • Proper load handling

Electric Pallet Jack

The key to training is reducing pallet truck risk. Each year, hundreds of workers suffer severe crush injuries to their feet and toes as a result of pallet truck accidents, the majority of which are preventable. Therefore it’s vital that you and your staff understand your responsibilities and limit the risk wherever possible.

This course provides in-depth training for operators of powered walkies and pallet jacks commonly used in industrial, manufacturing and construction applications. Training includes Section 25(2)(a),(d) and (h) and Regulation 851 of the Occupational Health and Safety Act which provides the requirements for training and certification of powered lift truck operators. Training meets the CSA Standard B335-15. Pallet jack safety certification consists of classroom theory, a written test and practical hands-on experience.

May Forklift Training Special


Google ReviewExceptional quality and service. Left the training class with more than I expected. Looking forward to being a repeat customer. ~ Kevin Brown

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Forklift Licence – What To Ask When Calling To Find A Good Trainer

Choosing your forklift trainer isn’t as hard or as inconvenient as it may sound. Choosing your forklift instructor is the first step to getting your forklift licence. Obviously you’ll want to choose an experienced forklift trainer is committed to quality, patient, enthusiastic, highly skilled, and values the lives of others.The job qualifications of a forklift trainer closely matches those of an athletic sports coach because forklift trainers really are coaches in an industrial setting, imparting knowledge and encouraging their trainees to be the best they can be. Any forklift training class worth taking should be conducted on a pass/fail basis. You don’t want trainers going through a program where everyone passes regardless of competency. Contact us to get started with your forklift certification today!

Forklift Licence

 

Let's Start Your Training Today!

 

What to Ask When Calling To Find A Good Forklift Trainer For Your Forklift Licence

No matter what the nature of your business is, if forklifts are used in your daily operation, you need adequate training for your staff. A good forklift trainer will train them in accordance with the Occupational Safety and Health Administration (OSHA) standard in the safe operation of forklifts. Proper training will help prevent  industrial accidents that may cause serious injury or death. It is mandatory for every company to comply with the present legislation. It is the job of the forklift trainer to make sure forklift operators are competent and knowledgeable enough, because if an operator is not adequately trained to handle and drive forklifts, they can cause more harm than good to your business. To help you find a good forklift trainer, here are some questions you need to ask them when calling.

1. Are you a qualified Forklift Trainer?Forklift Licence

A qualified trainer would be a person who:

  • Has a recognized degree, certificate, or professional standing
  • By knowledge, training and experience, has demonstrated the ability to train and evaluate powered industrial truck operators.
  • Is professional 
  • Has the right levels of experience from forklift trainers in order to produce safe and operational forklift operators. 
  • Is certified to operate a powered industrial truck according to OSHA standards and that the trainer
  • Has had their performance evaluated according to the provisions of 1910.178(l)(3) every three years. It is always important to ask for proof of their forklift trainer certification to determine whether or not  they have the proper qualifications.

What type of person makes a good trainer? This is something you need to put a lot of thought into, since it will make or break your forklift safety program. 

  • Person who desires to be a forklift trainer and expresses interest in the position.
  • Person with good verbal communication skills.
  • Person with a good safety record and who is not brand new to your company.
  • Person who already has basic forklift operational skills.
  • Person who is not afraid to confront those who are not following the rules for safe operation.
  • Person with good organizational and people management skills.
  • Person with basic computer skills, who can use PowerPoint and communicate via email.
  • Person who has successfully coached a team in their past; training is a lot like coaching.

 

2. What training classifications do you provide?

Forklift Licence
There are many types of forklifts used in different industries. When choosing a forklift training course you need to be equipment specific to your needs. Pick a forklift trainer that offers a variety of training in numerous forklift types as well as safety courses such as pedestrian awareness, fall arrest, propane cylinder exchange, WHMIS, lockout / tagout, battery and train the trainer. Just in case you enjoy teaching, maybe train the trainer could be for you. If you are looking for a new career skill, talk to the trainer to find out what the most common forklift is. 

3. Do you have a flexible forklift driving school schedule? 

Forklift Licence
A qualified forklift trainer can work with you and customize a schedule to suit the individuals or groups in your workplace and to fit with your ideal time frame. This will allow your company greater flexibility to choose training either at your site or at our forklift training center to help accommodate shift work applications. A good forklift trainer will custom-tailor their training to fit your business’ specific needs. Wayco has flexible schedules and excellent rates.  Our instructors are certified, very efficient, and helpful. Our affordable and flexible forklift training course offers a great way for everyone from novice forklift operators to experienced operators to learn how to drive a forklift, obtain refresher training, update their forklift training credentials, and much more. Check out the training calendar for scheduled dates. If these dates are not suitable, contact the trainer for a customized date.

 4. What will I learn in your class?Forklift Licence

Trainers need to be more than DVD inserters. Simply showing up and getting a piece of paper that says they attended is not acceptable by the trainer nor the OSHA. A trainee should improve their knowledge, learn with passion, identify and fix workplace hazards and remind themselves they should want to help others work safe. The training must be a combination of formal – such as lecture and video – and practical – such as demonstration and practical exercises – and include an evaluation of operator performance in the workplace. A good quality school will educate trainees in numerous topics about forklift safety, equipment operation, related OSHA regulations, workplace-specific subjects and in applicable law regulations. In addition to these, the school should provide an intensive course to address forklift maintenance and inspection that includes refueling, recharging, and basic troubleshooting. 

By the end of this forklift training, participants should be able to:

  • Explain operator competency
  • Discuss workplace hazards
  • Explain stability principles
  • Explain how to conduct pre-operational checks
  • Explain safe operating principles
  • Explain fuel source hazards

5. What is the duration of the course?Forklift Licence

Effective forklift training will depend on the complexity and comprehensiveness of the trainingThe standard training course, usually lasts for 4-6 hours; this is the time required in order to absorb many facts and information as possible. It is not advisable to enroll in a course that promises you to become certified in just few hours of training.The more complex the forklift the longer your course will take. For example, a rough terrain will take more time than a counter balance forklift.

6. Do you offer placement?

forklift licence

Are you wondering how to get a forklift job? Employers look for job applicants who have completed OSHA compliant forklift training. Most forklift trainers do not offer job placement, but some training facilities are affiliated with companies that do hire forklift operators. 

If you are looking to start a new career, you can look for employment on the Wayco website in the jobs tab for placement agencies or companies looking to hire. Our employment assistance program to assist in quick job placement is just one of the things that makes it safe to say that WAYCO training is the first choice for forklift training and certification. Wherever you want to work, the pay is good, there are plenty of forklift jobs to go around and some of the main types of organizations that have forklift certified jobs to offer include manufacturing, construction, airports, and haulage depots.

7. What do I require for class?

Forklift Licence
Workers must wear appropriate work clothing which includes visibility jackets, hard hats, hard soled shoes, and they need to avoid loose clothing. Many providers don’t tell you what materials are available or what they cost until you attend their class and then it is too late. They undercharge for the training so they can overcharge for the videos and materials once they have you on the hook.

Wayco’s  training course requires you to wear proper clothing, work boots and bring the ministry required photocopy of ID. There are no extra costs for materials used but we do require proof of identification when you arrive to our class. It is also important to meet the ministry requirements for proper record keeping, photocopy of ID, copy of test and practical evaluation signed by the trainer are kept on file for 3 years. 

8. Do I receive updated notifications?

Forklift Licence

Wayco will handle updates and notifications for you. Three years after you receive your forklift certification, you are required to renew your expired forklift licence. You will receive notification one month prior to your expire date via email, mail or a phone call.  We will also update you on any new forklift information or updates regarding forklift training laws. The expiry date is printed on the bottom right corner of your licence card. You should update your contact details if it changes. OSHA inspectors conduct surprise inspections at work sites; you do not know when they will knock on your door. Always be ready. You do not want to get penalized and fined for thousands of dollars for every operator found not certified. Get all your operators trained and certified.OSHA is stricter and will always be protective of the welfare of workers and implementation of their rules and regulations, so keeping your certification renewed is important!

What To Ask – Infographic


You’ve worked hard to attain your goal. Training is just a small investment, but it could make a very big impact on your career. Always keep in mind that quality training is worth the cost. Remember forklift training reduces the risk of injury or even death. I am ending this article by wishing you good luck on your career!

Google Review~I have used Wayco twice, and both times I experienced excellent customer service . They had the right forklift for my needs at a reasonable price. I will be using their services in the future and recommend you do as well.~Gabe Gartner

 

 

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Automated Forklifts – The Ultimate Purchasing Guide

Automated Forklifts

Is there a new world of automated forklifts upon us? Will we even need humans to operate forklifts once the automated robots take over? Warehouse operations are more complex today than they have ever been. In today’s fast-paced business climate, customers increasingly demand and expect more from their warehouse and distribution centers. Customers today are finicky. They expect to receive their orders as quickly and accurately as possible, while receiving the highest level of service. Switching to automated forklifts may be you only way to keep up with these demands. If you are looking for more information about how your business can keep competitive, contact Wayco. We are happy to answer any questions you may have and help you create an effective solution to your warehousing needs.

Automated Forklifts

Contact Us for Warehouse Solutions

Amazon: An Automated Warehouse in Action

Amazon is a great example where automated robots are used effectively in a warehouse setting. These automated robots carry bins of product that people have ordered online to the associates who then pick out the item that their customer has ordered. Instead of humans walking to find that item, the item comes to them now. By a scanning QR codes to detect their path and moving in different directions within a grid, these robots cleverly move to where they are needed. It is impressive to see several robots, each carrying about 700 lbs of materials, each one waiting their turn to be sorted.

It is a real challenge to have different machines move around on their own, in a given space, especially since each one weighs about eight tonnes. By using built-in sensor technology, the robots don’t crash into each other, even though they’re moving at 8 km/h. Tens of thousands of items leave Amazon each day – and for those who use Prime delivery in the GTA, they get their packages at their door mere hours later.

Will Automation Take Away Jobs?

The working relationship between man and machine is part of a typical day at a Amazon. Automation has allowed a quicker turnaround in supply and shipping in places. Some have argued that the use of machines in warehouses will take away jobs. On the contrary, Amazon says they have been able to grow their workforce because of the use of robotics. Amazon’s New Jersey automated center has the largest workforce with more than 3,500 full-time employees.  Brampton has 700 full-time employees, with an additional 200 hired last month, working in this 855,000 square feet. Amazon has opened a fulfillment center every year in Canada since 2011, starting with Mississauga, then growing into a second Brampton location and Milton, plus two warehouses in British Columbia.

Westfalia: Optimize Your Warehouse

Westfalia is an automated storage & retrieval system that combines software development with machinery from pallet flow systems, conveyors, order pick systems (pick-to-light, pick-to-voice, etc), layer forming and robotic palletizers, automated parking systems, and stainless steel case packing, stacking and handling equipment. Westfalia’s flexible automated storage and retrieval systems (AS/RS) consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations. The computer determines where in the storage area the item can be retrieved from and schedules the retrieval.  It directs the proper automated storage and retrieval machine to the location where the item is stored and directs the machine to deposit the item at a location where it is to be picked up. A system of conveyors and or automated guided vehicles is sometimes part of the AS/RS system. These take loads into and out of the storage area and move them to the manufacturing floor or loading docks. To store items, the pallet or tray is placed at an input station for the system, the information for inventory is entered into a computer terminal and the AS/RS system moves the load to the storage area, determines a suitable location for the item, and stores the load. As items are stored into or retrieved from the racks, the computer updates its inventory accordingly.

They have the ability to adapt to changing market conditions now and in the future implementing warehouse solutions to manufacturers and distributors utilizing a variety of loads. Westfalia’s theory is “Warehouse storage space is expensive, so it makes sense to make the most of your warehouse storage capacity in order to reduce carrying costs and increase material handling efficiency.” 

Recently a private label bottled water industry installed an AS/RS system for their residential and retail clients sizes ranging from single servings to five gallon bottles. Now it operates in one aisle, each capable of handling two pallets at a time. Rack entry vehicles quickly and smoothly store and retrieve pallets from the four level rack which holds over 6,500 pallet positions in 10 pallet deep storage lanes. In a few short months, a marked improvement in safety has already been noticed due to significantly fewer forklifts being used for warehousing. An updated accurate full inventory can be obtained with a push of a button! 

Warehouse Automation Can Cut Long-term Costs

One fact exists, warehouse automation stands as one of the last areas where long-term costs can be significantly reduced. Many vendors with automated robotics have undergone numerous tests with their automation and have found that it operates almost flawlessly.  As in all major capital purchases, cost is a big consideration. It is important to remember that over a 25+ year life cycle, the initial cost lessens when taking into account the annual profits, which are usually related to labor cost reductions, a smaller footprint, and higher customer service levels. So basically a 25+ year life cycle can be achieved in 5 years or less. Warehouse automation can give a company new opportunities for higher productivity, better space utilization and greater economic justification.

What Purposes Do Automated Forklifts Serve?

Automated Forklift Equipment

 But let’s go over exactly what automated equipment can do and what they can not do in the whole warehouse process. Automated robotics has allowed a quicker turnaround in supply and shipping in places. Robotics can boost your productivity, reduce product damage, and optimize your facility, reducing costs and increasing efficiency and profitability. One fact exists, warehouse automation stands as one of the last areas where long-term costs can be significantly reduced. Another great factor is safety, it will eliminate fork truck related accidents as well as eliminate any facility and equipment damage by conventional fork trucks. There is also a reduction in mis-shipments and product loss with automated machinery.  Bottom line is that they can achieve a higher customer satisfaction levels which in turn will create future growth. But don’t worry about machines taking over. The cool thing about humans is that we are still needed to operate the machines; to actually get things done. Plus, who’s going to repair these automated forklifts when they need maintenance; and someone has to drive the product to the customer or check the product for damage.

What you need to know before buying

Substantial benefits and significant labour savings can be provided by automation. Unfortunately, if you make the wrong choices, you can burn a hole in you wallet getting little, if any improvement over what could have be done with traditional solutions. To determine whether or not they are right for you, you will need to weigh the benefits and drawbacks and decide whether they would hinder or complement your business.

Automated Forklifts

Here are a few simple rules to help you make a decision when investing in automation:

  • Purchase high-quality equipment
  • Design for expansion
  • Remember that long term planning automation occurs over the course of several years
  • Training Costs for new equipment’s operational and safety procedures
  • Calculate the cost savings
  • Personnel should be part of the project team from the start; do not wait unit system goes live
  • Be proactive; it’s less expensive to follow recommended preventive maintenance schedules
  • Select your vendor carefully; check references and experience
  • Make a list of the benefits

Where to buy

Automated solutions can solve challenges today and ensure that you’re ready to react more quickly to business disruptions.  Labour costs are rising and automated forklifts are ideal for tasks that are tedious and labour intensive, but do not require much skill like Diematic Mobile Automation. These mobile robotic automated guided vehicles can move and transport items within production, warehouse and distribution environments. Maybe you need a solution for warehouse space?  Earlier we talked about warehouse solutions from Westfalia Innovative Solutions custom automated storage and retrieval solution a leading provider of logistics solutions with over 100 installations in North and South America. Today, the sales of  automated forklifts vendors are on the rise. You can purchase them from companies such as Transbotic, Diematic and Kollmorgen . These are just a few vendors, but remember what you need to know before buying.

Automated Forklift

Advantages and Disadvantages of Automated Forklifts

To help you determine whether or not they are right for you, here are some of the major benefits and drawbacks of using Automated Forklifts.

Advantages

  • Repetitive – with little variation, shift after shift
  • Optimized space utilization 
  • Reduced labor and equipment costs. 
  • Less product and waste damage
  • Lower maintenance costs
  • Lower energy costs
  • Organized inventory
  • Increase efficiency
  • Shipping Accuracy
  • Safety eliminates truck related accident

Disadvantages

Of course, there are some disadvantages to using robotics. These include:

  • Can’t always adapt to changing situations
  • Product label could be unreadable, show as an error
  • Initial cost of equipment is high
  • Not suitable for non-repetitive tasks
  • Potential Job Losses
  • Hiring or Training Skilled Staff
  • Possible down time due to malfunctions
  • Maintenance Costs

Canadians may be slowly outsourcing themselves to robots – and that may have a significant impact on the economy, according to an automation expert. Right now, drones are being tested for deliveries, eliminating more potential jobs. With this growing boom, the last decade has seen Automated Forklifts become integrated in many industries outside of distribution and manufacturing—such as retail, the military, and even healthcare.

Google Review ~We purchased a used fork lift from Wayco in January. It was extremely clean and in excellent condition when it was delivered. We have also had incredible ongoing service from the professionals at Wayco. Overall dealing with them has been an excellent experience.~ Dons Trailer

 

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Rough Terrain Load Lifter – Everything you Need to Know

rough terrainRough Terrain Load Lifter – Everything you Need to Know

What is a load lifter? A load lifter is a rough terrain forklift also known as a  deep reach truck because it can ultimately reach double deep for construction, industry, agriculture and mining situations. It is used outdoors in challenging conditions. “Rough Terrain”  means literally, any ground that isn’t smooth. This would include hilly, rocky, bumpy, and mountainous terrains. Forklifts generally fall into two categories: industrial and rough terrain. Industrial forklifts are commonly used in warehouses and around truck and train loading docks.  Rough terrain forklifts are designed to run on rough, unpaved surfaces and have large pneumatic tires. These forklifts are powered by an internal combustion engine running on gasoline, diesel or propane fuel. Rough terrain forklifts can have a vertical tower, which lifts loads straight up, or a telescoping boom, which lifts loads up and out from the base of the machine.

So whether you are in lumber, mining, agriculture, construction or any other industrial business, the rough terrain load lifter design may be right for your challenging environment. It is considered the premier type of telehandlers and vertical mast forklifts. If you have to move material across uneven, difficult terrain Contact Us, to find out if this load lifter is for you.

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Rough Terrain Forklift

Load Lifter 

Load Lifter is a world leader in the production of rough terrain forklifts and has produced high quality forklifts for these markets. It has lead the way with innovative design and value priced vehicles. Load Lifter was one of the first North American manufacturers to build a true four wheel drive, four wheel, steer and rough terrain forklift. They now have five series of machines representing a total of more than twenty-eight models ranging from 4,000 to 30,000 lbs and lift heights from 8 to 42 feet to choose from. Today, rough terrain forklifts are a common sight on construction projects. They handle everything from pallets of concrete block to stacks of plywood to roof beams. 

A Load Lifter rough terrain forklift is four wheel drive making it the perfect choice to work during winter and spring weather conditions. This forklift utilizes four equal sized wheels and offers four wheel steering. This makes it very maneuverable with superior performance in deep mud and snow.  Standard lift trucks typically have four uniformly sized tires of the same width where a load lifter has significantly larger front tires that support the heavy lifting while using smaller tires at the rear for steering. The tires have deep treads and are foam filled which eliminates the threat of punctures on any surface. Unlike standard trucks that operate on relatively smooth surfaces, rough terrain forklifts are used on gravel lots, plowed fields, hillsides, bogs and rough cut construction sites as well as paved surfaces.

A rough terrain forklift has many good features including:

  • roomy well equipped optional cab assembly
  • larger operators compartment and generous leg and foot room
  • excellent operator access on and off machine with adjustable tilt steering column
  • adjustable seat height from the operators position
  • finger tip steering even at low engine idle

Just because they are big in size doesn’t mean you can’t ride in comfort. Load lifter does have a quieter operation than most due to increased insulation and anti-vibration technology. The rugged and maneuverable compact Load Lifter rough terrain has a straight mast which is much wider and able to reach higher than a standard lift trucks. The standard lift truck has a two or three stage mast lifting with a usual maximum height of 189″, but the  Load Lifter can lift up to 504″; that’s almost double the lift. The forks will be longer depending on the size of the forklift. The mast on Load Lifter is the leader in visibility and sight lines and it’s powered by an EPA compliant diesel engines. Load lifter makes a variety of rough terrain models designed for specific purposes for different industries.

Telescopic Handler

Rough Terrain Forklift

The new generation of Load Lifter Telescopic Forklifts can make your life easier and will be a strong competitor in the construction and rental sector of the equipment business. The telescopic handler is a far more popular model of Rough Terrain Forklift in the United States than it is in Canada; and it continues to remain that way today.  This machine was built with a componentized power train and a purpose built frame. Many other manufacturers used converted agricultural tractors for their machine base, but these were difficult to service and repair if a major component was required to be removed.  These machines were produced with capacities from 6 through 12 thousand pounds and lift heights of up to 30 feet.

Laborer Series

Rough Terrain Forklift

Load Lifters builds the Laborer series rough terrain machine for the mining industry which required a specific application for underground use. Miners had several issues with low ceiling heights and very small cages to transport their work equipment from level to level. They also had a need for a forklift that would be capable of climbing steep grades and be able to meet very strict safety requirements. These units were extremely compact and rugged, and were able to fit in areas that conventional rough terrain forklifts could not. Four wheel drive was offered as an option which was not typical for industrial forklifts of similar capacity. The first unit was built as a mine application machine with very specialized options that met the specific requirements. With such positive responses to the mine version, they released a more economically priced aggressive forklift. This machine was utilized by paving stone, recreational vehicle and utility companies. 

Agri Lifter

Rough Terrain Forklift

The turf industry approached Load Lifter to build the Agri Lifter. This industry needed a heavy use, vertical mast rough terrain forklift that was also light and agile, specific for their application. They had been using a construction type designed machine that in many cases was too heavy. The Agri-lifter series is available in 4-5000 lb capacity. Agri forklifts have higher ground clearance allowing greater articulation and easier movement across uneven ground without grounding, damaging undercarriage or bogging the unit. Agri Lifter has a higher ground clearance allowing greater articulation and easier movement across uneven ground without grounding, damaging undercarriage or bogging the unit.

To improve on the rough terrain Load Lifter, a wide variety of attachments has been developed to improve their utility such as winches, booms and rotating fork carriages allowing it to place materials more accurately. Articulating booms, or booms with two separate extendible arms, can reach up and over structures to place loads on interior roof slopes or in the center of upper floors.


Advantages of the Rough Terrain Forklifts

  • Carry huge amounts of material at a single time and provide back support to the lift
  • Have more accurate steering response and precision
  • Easier to change lanes at high speeds without the risk of going into a spin
  • Calibrated counterbalance at the back of the forklift prevents it from becoming overbalanced
  • Higher ground clearance allowing greater articulation and easier movement across uneven ground 
  • Diesel engines to provide the extra power necessary to operate over rough terrain while carrying heavy loads
  • Navigate slopes with gradients of up to 38% offering superior operation over rough terrain

Disadvantages of the Rough Terrain Forklifts

  • More expensive construction since vehicles with four wheel steering cost more
  • With pricey construction comes higher maintenance cost
  • If tires are air filled there’s a possible hazard of punctured pneumatic tires
  • Designed for outdoor use only
  • Higher cost of fuel
  • Need a large storage area 

Watch this Load Lifter video and keep your eye on what the mast and forks are capable of doing! 

                                                                                                     


Why You Need to Take the Rough Terrain Training Class 7

According to OSHA, rough terrain forklifts are classified as class 7 forklifts, and include three primary types: vertical mast rough terrain forklifts, variable reach rough terrain forklifts, and truck or trailer mounted rough terrain forklifts. The rough terrain forklift can carry heavy loads and should be driven carefully like a regular forklift as it also has the risk of tipping over, rollovers and collisions.. Drivers of these vehicles have more reason to be concerned about safety; so operators need to be provided with the proper training to operate a rough terrain forklift.  Being extra cautious is never a mistake as it guards you against dangerous accidents.

Rough terrain forklifts are more commonly used today in the construction industries and there is also a great potential for misuse, operator error and possible accidents by untrained workers who may not recognize potential hazards. Learn how to avoid hazards and how to navigate through various situations to prevent accidents. Neglecting to train workers now has serious financial and legal implications. The rough terrain training will ensure you’re compliant with industry standards. According to OSHA, all forklift operators must receive training that consists of written instruction, practical training, a rough terrain forklift test, and an evaluation. It must cover both rough terrain forklift truck related and workplace-related topics, and be led by a qualified trainer. Like the standard forklift training you will be trained on a pre-operational check, loading and unloading, stability and handling, and fueling in a safe manner.

Training is the key to a safe, long and successful career!


Google Review~We purchased a used fork lift from Wayco in January. It was extremely clean and in excellent condition when it was delivered. We have also had incredible ongoing service from the professionals at Wayco. Overall dealing with them has been an excellent experience.~Don’s Trailer

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What Power Should I Choose for my Forklift? Electric vs Diesel vs LPG Forklifts

So how do you go about choosing the most suitable engine type for your forklift? Electric vs Diesel vs LPG Forklifts. What is the best fuel type to choose? We review the three types to help you make an informed decision when acquiring a new or additional forklifts for your business. Before you get in touch with us here are a few things you ought to know.

Electric vs Diesel vs LPG Forklifts

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What Power Should I Choose for my Forklift? Electric vs Diesel vs LPG Forklifts

Electric Forklift

Because they are compact, electric-generated lift trucks can get around tight spaces, not to mention the fact that they are easy to operate. You pay a high price tag upfront though. The electric forklift is ideal for working indoors due to their low emissions, but just like the automotive industry, advances in the electric lift truck designs are now allowing them to be utilized in more outdoor applications than in the past. Those with seal components, including motors, controllers and connectors can also be used outdoors. Energy efficiency is a key factor to consider when selecting an electric lift truck. Although, it is important to factor in that batteries still require electricity from the grid, they have zero emission, which means a safe and healthy environment.  That is why these can be called the Green Forklifts.

Electric vs Diesel vs LPG ForkliftsRun times are critical to productivity for your operation, so the biggest consideration is the recharging process. A typical battery for an electric forklift will take 8 hours to recharge completely and then an additional 8 hours to cool down before it should be used. For example, a single charge could last from 3 to 12 hours depending on the application and other factors. You may have to consider additional batteries if your operation has multiple shifts. We spoke about the high maintenance of a gas forklift, well batteries for the electric forklift need proper maintenance to extend the battery life. Electric lift trucks operate on battery power, resulting in considerable less maintenance than the engine powered machines due to the fact there are less moving parts. Electric forklift have no clutch or inching pedal, they only have an accelerator and brake pedal generally making it easier to drive than engine powered machines. 

Warehouses can take advantage of an electric forklifts’ superior maneuverability and enjoy their quiet, but faithful services because the battery weight of an electric forklift acts as an effective counterbalance. Electrics have a  3 wheel design which is great for narrow aisles due to their small and delicate turning ability. They also come in 4 wheel options offering stability and gradeability to help you handle heavy materials in steeper environments. Electric forklifts have a low center of gravity, so they are more stable at greater heights. In comparison to the propane forklift, the electric forklift is slightly easier to see behind the machine. The operator will have better vision when determining if the rear path is clear.

Electric vs Diesel vs LPG Forklifts

The sky is the limit for fuel cell forklifts making the material handling industry a green one. Not only is this good for the environment but it’s also a bonus for employees in the workplace. The advantages now far outweigh the disadvantages. It is clear why electric forklifts have played an expanding role in equipment fleets with their safety, performance, and environmental strengths. For the average business owner who is looking for a good long term investment, going electric for material handling in indoor areas is an easy choice.

There has never been a better time to “go green” and take advantage of the advancements made in operating an electric forklift fleet.  By doing so you will have a safer and cleaner facility, reduced operating costs, and you will leave a smaller footprint behind while you improve the profits of your material handling operation.  

DISADVANTAGES

  1. Can not be used outside in wet weather for prolonged periods of time
  2. Initial cost of the forklift is much heftier upfront because of the battery and charger
  3. Cannot be used during recharge mode and can seriously slow down your work pace
  4. 8 hours to charge a battery
  5. Battery changing station (200 sq. ft) which further limits your storage space
  6. Charging area needs to be dry, ventilated and temperature controlled
  7. Changing batteries can be quite difficult as they weigh over 1,300 kg
  8. Batteries last for roughly five years
  9. Performance will degrade as the battery reaches 80% discharge
  10. Batteries are expensive
  11. Electric forklifts are limited to availability over 12,000 lbs
  12. A better floor surface is needed

The technology of electric forklifts is growing every day and sales have outpaced that of traditional internal combustion forklifts for a few years, but electric forklifts are not suitable in all applications.

Propane (IC) vs Electric Operational Cost Calulator

This calculator will give you your operational cost difference for propane vs electric forklift by purchase price and maintenance.

Electric vs Diesel vs LPG Forklifts

Diesel Forklift

Diesels forklift need diesel fuel to run, which is more affordable than the electric forklifts. Diesel powered forklift trucks are ideal for applications where they are mainly used outside. Diesel also lasts longer as than other fuel types. Diesel forklifts have some of the most affordable long term operating and fuel costs among internal combustion forklifts.  Diesel forklifts are more powerful and can out-lift the average electric forklift too. Exhaust catalysts and purifiers can reduce exhaust emissions and make the machine acceptable for occasional indoor use. Diesel forklifts are not adversely affected by wet or damp weather. Therefore it’s recommended that you get a diesel forklift if you need to do heavy lifting or if you use it outdoors in climates that experience harsh winters or hot and humid summers.

Electric vs Diesel vs LPG ForkliftsThe biggest advantage is their low operating costs. Diesel forklifts are the cheapest fuel option, they can be refueled on-site, and they are immediately ready to go. Sure you don’t have to refuel an electric forklift, but they are not cut out for outdoor environments the way diesel forklifts are. Comparing diesel with gas forklifts, the diesel fuel systems are internalized where propane engines are either external or rear-mounted and usually the diesel engine lasts significantly longer than propane engines. You will also have fewer maintenance issues as a diesel forklift requires less scheduled and repair maintenance and has longer engine life compared to propane models.

Diesel forklifts are considered better in industrial applications or carrying heavier loads. Extra attachments can be added to a diesel forklift, like hydraulic attachments which do not affect its power nearly as much electric forklifts. The more components that need power for electric forklifts, the faster the battery and overall power of the forklift is depleted. The higher torque of a diesel engine forklift compared with an LPG truck makes it better on gradients and more powerful for towing duties or when used with a bucket on the forks for scooping aggregates, etc. When it comes to disposal, diesel forklifts usually have a higher residual value than LPG or electric machines. Diesel forklifts are available for use at any time of the day or night.

Disadvantages

  1. Emits toxic exhaust fumes
  2. Needs a well ventilated or open space area
  3. Cannot work their way around corners and tight spots
  4. Loud engines makes for difficult communication
  5. Cost of diesel can be higher than propane
  6. Cost of the big tank for storing the fuel can be higher then the cost of the forklift
  7. Diesel forklifts are expensive to buy and expensive to run
  8. Fuel prices are predicted to increase over the years
  9. Requires more consumable parts – emissions maintenance, filters
  10. Fuel emissions are not eco-friendly
Gasoline and diesel engines are the two most commonly used internal combustion engines even though their operations seem similar they have some interesting differences and each has advantages over the other. The following video is aimed at exploring these differences.

                                                                             

LPG Forklift

Enter any industrial facility or warehouse,and chances are you’ll see propane forklifts in use. In fact, more than 670,000 propane-powered forklifts are in use in industrial, manufacturing, and construction businesses all over the country. When it comes to usability, having a forklift that can be used both indoors and outdoors without any decrease in safety or efficiency is a plus. Propane trucks are becoming more eco-friendly, affordable, and safe.

Electric vs Diesel vs LPG ForkliftsInternal combustion forklifts are the most common forklift used to pull, push, carry, stack, lift or tier materials inside and outside. There are two types of gas forklifts.They can either be Liquid Propane Gas (LPG) or Petrol Gas. Although it is true that propane emission numbers can’t compare to the zero emission of electric, it is considered clean enough for indoor use and is safer to use than other gases except if there are food or beverage requirements. Propane forklift generates better performance, better horsepower and torque than electric forklifts. Easy to refuel, only replace the empty propane cylinder with a full one. Initial purchase price or capital cost is lower when compared with electric and diesel forklifts. Their travel speeds, rates of acceleration, and lift speeds usually outperform their electric/diesel rivals because of better power to weight ratios and more responsive engines. LPG storage cage saves valuable indoor storage space when compared to an electric recharge station, as the LPG is stored outdoors.

An LPG engine will heat up faster due to the cylinder head temperature, even with a cold engine. The power you start the shift with will not waver or decrease as time goes on. As long as there is fuel in the tank, your forklift will operate at full capacity. Propane forklifts have more varieties of options to choose from. In addition, propane engines can last up to twice as long as their gasoline counterparts saving you money on maintenance.

Disadvantages

  1. Exhaust fumes can leave hydrocarbon particles on surfaces
  2. Propane lifts are less effective than diesel models when it comes to torque
  3. Individual operator must be trained on its proper propane handling
  4. Repair maintenance costs are greater than diesel and electric forklifts
  5. Restricted rearward visibility due to the tank location
  6. Future costs of propane are predicted to increase over the years
  7. Gas forklift has greater emissions compared to propane,
  8. Requires a greater amount of space for fuel storage
  9. Forklift operator could get hurt lifting a heavy propane tank
  10. Higher costs when compared with electric.
  11. Freezing temperatures may cause starting or reliability issues.

Summary

Each forklift has its own unique advantages and disadvantages. It is important for warehouses to examine their personal business needs and tailor their purchases towards the type and nature of their material handling. The main factors to consider when making your decision should be to take into account how long you need to be operating your forklift for every day, what type of surfaces will your forklift will be navigating, will your forklift be operating in a confined space and how much do you want to outlay for purchasing and running costs.

Contact us for further information on forklifts or other industrial equipment.

Google ReviewI have used Wayco twice, and both times I experienced excellent customer service . They had the right forklift for my needs at a reasonable price. I will be using their services in the future and recommend you do as well.~Gabe Gartner

 

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