10 Frequently Asked Questions Pertaining to Forklift Training

When it comes to training for these trucks, there are specific OSHA requirements that must be met. Below are some frequently asked questions related to forklift training.

1. What vehicles are considered to be powered industrial trucks?
The American Society of Mechanical Engineers (ASME) defines a powered industrial truck as a mobile, power propelled truck used to carry, push, pull, lift, stack, or tier materials. Powered industrial trucks, often called forklifts or lift trucks, can be ridden or controlled by a walking operator. Excluded from the OSHA standard are vehicles used for earth moving or over-the-road haulage.

2. How has OSHA changed its powered industrial truck standard?
Previously, the OSHA standards required that any trained operators could operate powered industrial trucks with just generic operator training. The new standard requires employers to develop a training program specific to the type of truck to be driven and the working conditions encountered. Employers must also evaluate the operator's performance in the workplace and certify that each operator has received the training needed.

3. What industries are covered by the new standard?
The new standards cover general industry, maritime and construction. The general industry standard is 1910.178(1).

4. Where can an operator obtain the training to become a certified forklift operator?
The employer is responsible for implementing a training program and ensuring that only trained drivers who have successfully completed the training program are allowed to operate powered industrial trucks. An evaluation of each trained operator must be conducted during the initial training, at least once every three years, and after refresher training. The training and evaluation may be conducted by the employer, if qualified, or an outside training organization. Shoppa's Mid America offers both OSHA compliant operator safety training and "Train the Trainer" programs. Operator safety training classes are offered once a month and are available on-demand at your location. Visit our website to learn more and see a schedule of upcoming classes.

5. What type of training is required?
The training must be a combination of formal (lecture, video, etc.) and practical (demonstration and practical exercises), and include an evaluation of operator performance in the workplace. Truck-related topics must be included, along with the requirements of the OSHA standard. The specific training topics are listed in the standard.

6. Who should conduct the training?
All training and evaluation must be conducted by a person with the necessary knowledge, training and experience to train operators and evaluate their competency. This may be the employer, another employee, or other qualified person. The training and evaluation does not have to be conducted by a single individual, but can be done by several persons, provided each one is qualified.

7. Is refresher training required?
Refresher training is required when the operator has been observed driving unsafely, been involved in an accident or near-miss, received an evaluation that indicated unsafe operations, is assigned to drive a different type of truck, or if a workplace condition affecting safe operation changes. An operator evaluation is required after refresher training.

8. What does "certified" mean?
The employer must certify that each operator has been trained and evaluated as required by the standard. The certification must include the name of the operator, the date of training, the date of evaluation, and the identity of the person(s) performing the training or evaluation.

9. Does an operator who has already been trained as a powered industrial truck operator have to be retrained under the new law?
If an operator has received training in a required topic and the training is appropriate to the truck and the working conditions encountered, additional training in that topic is not required if the operator has been evaluated and found competent.

10. Where can I get additional information about OSHA and the new standards?
For more information, contact your local or regional OSHA office or visit www.osha.gov. You can also contact Shoppa's Mid America today to get a free safety evaluation by one of our certified trainers.

Distracted Driving is Dangerous - Even on a Forklift

Most people would agree that distracted driving is a worldwide problem; however, they might also think that it is one which does not apply to them. It doesn't matter if you are operating a service van, semi-truck, car, or a forklift; distractions can cause injury or death to the vehicle operator, to other drivers or to pedestrians who are unlucky enough to be at the wrong place at the wrong time.

Eating while driving, passengers or the radio are some of the biggest diversions when it comes to driving a car, but certainly not the whole realm of distractions in today's world. Drivers today deal with cell phones, text messaging, surfing the web on their phones, DVD players, navigation devices, MP3 players, complex sound systems and much more.

The problem in the material handling world is that people are bringing poor habits from their personal vehicles into the workplace and on to powered industrial trucks. Distractions on forklifts include two-way radios, FR scanning equipment, eating and drinking, cell phones, music playing devices, pedestrian traffic and fatigued driving just to name a few. As far as radios, RF scanners, cell phones and music players go; smart companies will put in place a policy which says "these types of devices may not be used while in motion, no exceptions." Make the first offense a formal write up and time off and the second termination and your rule will be very effective.

Food and drink is another area of concern. Companies which want to avoid the chance of accidents in this area will advise operators to keep food in the lunch room. Even if operators are not eating or drinking while in motion, the chance of a spill or drip while in motion and the subsequent distraction, is too great. Hot and cold liquids which are spill on operators result in many auto accidents each year, as do the dropping and retrieval of unsecured items. It does not help that many manufacturers are now building cup holders into their dashboards; it only encourages operators to bring along things best left behind.

Another problem is drowsy driving. According to the National Highway Transportation Safety Administration, drowsy driving causes more than 100,000 auto crashes per year in the US. These crashes result in 40,000 injuries and 1,550 deaths. There is no doubt that all types of vehicle operators, including forklift operators, suffer from fatigue, with long shifts and odd working hours. Night shift workers suffer the most from fatigue, as the distractions of trying to sleep during the day, when everyone else is awake, are many. Most people can handle getting too little sleep one night fairly well, but the effects of sleep deprivation night after night are cumulative and can be harmful both physically and emotionally. Many people also work rotating shifts, where the body never gets a chance to adjust to one set schedule, causing problems with sleep patterns. The answer to this problem is likely twofold, consisting of education for your operators and also keeping a close watch out for potentially exhausted workers. If operators can take steps to get more sleep, understand the effects of fatigue on their bodies, and learn to know their limits, it will create a safer working environment for them and others. Supervisors must also be watching for the early signs of drowsy driving and assigning those people to non-driving positions for the rest of the shift, somewhere where the consequences of sleepiness would not be dangerous.

Shoppa's Mid America offers OSHA compliant safety training courses once a month and on-demand at your location. Our certified trainers are also happy to visit your facility and provide a free safety evaluation. Visit our website to learn more, see a schedule of upcoming classes, or to request a training session.

10 Ways to Improve Material Handling Efficiency

If your distribution center is running at peak performance, congratulations. Keep up the good work. Chances are your company is enjoying the fruits of this success. Throughput is flowing flawlessly and the competition is running for the hills. Times are good.

But if you think your distribution center can run more efficiently, that throughput can still be increased, costs could still be lower, and manpower could be better utilized, then here are 10 ways to improve your warehouse efficiency.

1. Gain an understanding of the current state of your distribution center.
Let's start with the basic premise, "You don't know where you are going until you know where you are." This means you must first measure and capture all data relevant to your company's operation. This would include labor expenses with overtime separated out, number of orders processed in a given amount of time, number of lines pulled by each operator, number of forklifts in operation during that time and the expense of leasing or operating each one, overall utility costs to run the distribution center and total cost per square foot of operating space in your facility.

2. Have a clearly developed customer service policy.
The most important question you should ask yourself is "What is my commitment to my customers?" The answer could be as simple as: One hundred percent of all customer orders received by 4:00 pm will be processed and shipped to the customer as a perfect order with 72 hours. In this case, a perfect order would be measured by its successful on-time delivery, with no damage and all documentation and labeling complete and accurate. Determine what is realistic and achievable for your organization and what will position you in front of your competitors. Develop your internal processes to achieve that high level of service.

3. Measure and record how many time an item is touched from the time it is ordered until the time it leaves the building.
Look for ways to eliminate handling items twice, keeping in mind that every time an item is touched there is the opportunity for human error. For example: Instead of picking items into a tote first and then dumping them out on a table, only to be re-packed into a carton, why not pick items directly into the shipping box?

4. Business can start picking up when companies start looking up.
Traditionally, companies tend to expand their operations laterally as they grow and the number of stock keeping units (SKUs) increases. It's easy to forget that your facility may have more available overhead space that can be utilized. By elevating some or most of the processing, packing or picking operations, use of free cubic overhead space may allow the distribution operation to extend the number of years within the existing facility. This bodes especially well from an economic standpoint for companies with favorable lease rates or those that own their building outright.

5. Gather data on the SKUs you currently have in inventory frequently.
Slot your facility carefully to ensure that each SKU is mapped for the shape, weight and velocity of its particular use. Identify how fast the items move from a demand perspective, according to class and make sure the most active SKUs are assigned to locations closest to input/output points in order to maximize throughput efficiency. Measure the dimensions and weights on all existing and in-bound SKUs. This can be accomplished accurately by using a CubiScan or other suitable measuring device. Knowing the volume of each SKU will allow you to slot efficiently, facilitate accurate check weighing, if appropriate, and accommodate current and future picking technologies. The data also allows you to take advantage of the cubing features of most Warehouse Management Systems (WMS) in order to calculate the appropriate-sized carton to use for a respective order. The difference between using a larger and smaller carton when shipping an order may not seem like a high-priority decision. But a smaller carton costs less and reduces the dead space that usually requires fillers such as Styrofoam peanuts and plastic pouches.

6. Consider or re-think your current picking technology.
Assuming you have measured accurately the number of lines being pulled by each operator, now may be the time to evaluate the feasibility of using a picking technology such as Radio Frequency (RF), Pick-To-Voice or Pick-To-Light, thus eliminating paper based picking which may not be cost-efficient for your shipping needs. Factors in making the proper picking technology decision should include density of SKU locations, required throughput, characteristics of the items you are picking, and any specialized procedures in place, such as serial number tracking.

7. Select the picking method that is right for your company.
Evaluate the merits of piece picking, where a picker picks one order at a time by walking up and down each pick aisle until the entire order is complete. How cost-effective is this versus, say, batch picking (a picker picks all orders at the same time in the same pass), zone picking (pick area is broken up into individual pick zones, similar to an assembly line), or wave picking (all zones are picked at the same time, rather than having orders move from zone to zone)?

8. Practice task interleaving.
This refers to the process and method of combining your active picking with the put-away process. Warehouse Management Systems (WMS) utilize logic to direct lift truck operators to put-away a pallet while enroute to the next full pallet pick. For example, if a forklift operator receives instructions to put away a pallet, the WMS will initiate a pallet pick so the forklift operator does not come back without a load. Since the average forklift operates on a 33.5 lb. LP tank, that costs an average of $25-$30 to fill, with a tank life of only about eight hours, you can see the cost-effectiveness of not coming back empty-handed.

9. Keep system downtime to a minimum.
Conveyors, carousels, palletizers and other devices such as tapers, case erectors, and stretch wrappers require planned maintenance. Equipment should be inspected, maintenance records stored with easy access, and small problems corrected immediately. Automated distribution centers should conduct planned maintenance at regular intervals, particularly belt tracking for conveyors, taking motor temperatures and lubricating as necessary. Spare parts, such as motors, belts, bearings and rollers, should always be on hand. The investment in a good maintenance plan will keep your orders moving and protect large investments in replacing equipment minimally.

10. Examine your equipment's vulnerable points from a power management perspective.
Mother Nature is not always a friend to a distribution center. If lightning issues or erratic power outages are frequent in your area, protect your distribution center from potential power spikes by using surge protectors and conditioning your service from the local electric utility provider. Don't let the minimal cost of surge protection cause major damage to your equipment or wipe out the programming in your controls. Remember, one damaged power supply can shut down a sorter, resulting in hundreds of thousands of dollars in overtime and delayed transportation expenses.

These 10 ways to improve your material handling efficiency can help increase the amount of perfect orders being shipped, and in so doing ensure customer satisfaction and promote increased sales. And along the way you've successfully answered that all-important question, "What is my commitment to my customers?"

Shoppa’s Mid America offers a wide variety of resources and services to maximize your warehouse space, increase your productivity and enhance your efficiency. Our professional warehouse systems specialists can even design and install a custom plan to improve your operations. We understand your diverse warehouse needs. Your entire facility should be organized, efficient and safe, and that's why we offer a one-stop shop for a wide variety of warehouse products, including pallet rack, shelving, dock equipment, safety accessories, workshop equipment and more. It's our goal to help you create the safest, most productive work environment throughout your warehouse. From office area to loading dock to employee breakroom, let us provide all the products and services you need for a streamlined, safe and efficient facility. For more information about our warehouse products and services, please contact Shoppa's Mid America today.

Purchasing Pre-Owned Forklifts Makes a Lot of Sense: Here's Why!

The truth is that companies close and relocate on a regular basis in today's fast-paced world, but the silver lining is that it translates to good used equipment purchase opportunities for small, mid-sized and even large operations.

Used forklifts, sweepers, scrubbers, aerial lifts, pallet rack, and booms enter the marketplace whenever a company has chosen to move on or close its doors. Much of this equipment comes from reputable mid to large sized companies that adhered to the ideal of a strict preventative maintenance (PM) practice that serves to protect the equipment from extensive damage. Many pieces even have full maintenance (FM) packages from their original purchase. This, in turn, represents a fantastic opportunity for smaller companies and even mid to large sized companies to capitalize on purchasing high-grade warehouse equipment for nearly half the price as it would cost brand new.

While the influx of used forklifts and material handling equipment has created a unique opportunity for buying quality products are reduced prices, the question at hand is where to buy it.

One major factor to keep in mind when purchasing warehouse equipment is lead time. Many distributors of new equipment can have significant lead times, as units are usually customized for each independent user. Deciding to buy used forklifts, pallet track, or other warehouse equipment can often be a much quicker way to get the item in your facility, as some material handling dealers maintain in-stock used equipment which may work for your application. They usually are able to turn an order around in a week's time or less.

While the buyer's market for quality pre-owned equipment lasts, small, mid-sized or even large operations can take advantage of it to boost their production capacity at lower prices. Those that do so will be well positioned not only during the current economy, but also when the recovery starts to take effect.

Shoppa's Mid America carries a variety of used equipment from forklifts, to sweepers and scrubbers, reach trucks and order pickers, pallet jacks and racking. Visit our website to browse our available inventory.

Clean Up the Productivity and Efficiency of Your Facility Maintenance

It can be a daunting task to sort through the industrial and commercial floor cleaning equipment choices available today. With the variety of scrub paths, capabilities and sizes of machines, finding the right solution can be a challenge. It is important to start with questions like:

• Do I need sweeping, scrubbing or sweeping and scrubbing?
• How large is the surface area I need to clean?
• What is the frequency of my cleaning need?
• How wide are my aisles?
• What type of flooring is the machine to be used on?
• What is the debris that I am trying to remove from the floor?

If you're looking for machine solutions that will help reduce your total cost to clean, and people who can understand and meet your needs, then getting in touch with a product specialist and having them discuss the Advance line of industrial sweeper scrubbers could be just what you've been looking for.

The Advance product line has been helping in-house cleaners, contractors and facility managers improve their floor-cleaning programs for over 100 years. Advance is continually developing innovative products for industrial and commercial floor cleaning applications, products that deliver high cleaning productivity, multi-tasking capabilities, and easy maintenance.

As an authorized dealer, Shoppa's Mid America offers top-notch service and expertise in everything from cleaning program analysis to "how-to" answers for your toughest applications. Whether you are operating a single warehouse, a massive manufacturing facility or driving area, floor and lot maintenance is critical not only to employee and inventory safety, but also to the professional appearance of your workplace. Don't let budgetary restraints or chemical solution problems allow dirty floors to create a safety hazard or inventory values to be negatively impacted by airborne dust and dirt.

It's time to advance your cleaning program! Contact Shoppa's Mid America today to schedule your FREE DEMO of the Advance industrial floor cleaning line and review your commercial and industrial floor cleaning equipment applications.

Inspect Your Forks to Prevent Safety Hazards

Forklift forks are the hardest working part of a forklift, yet they are often mistreated and forgotten. As insubstantial as it may seem, neglecting forks could make them dangerous. A simple 10% reduction in blade thickness results in 20% reduction of capacity.

Most operator training manuals and training classes hardly mention the forks, but it is important to provide proper maintenance and inspection of forks to make sure they perform safely and productively. Under normal conditions, forks should be inspected daily by the operator with a visual inspection as well as being professionally inspected every six to twelve months to look for cracks, distortion, blade straightness and wear, among other things.

The best method for a fork inspection is a fork caliper. This adjustable go/no-go device measures four contact points on the shank and blade of the fork. The reading determines the wear of the fork for safety and usefulness.

Forks should not be loaded over the capacity of the forklift. The forklift operator should be aware of the capacity of the forks, since overloading will lead to bending or weakening of the forks. Following these guidelines should help prolong the life of your forks.

Fork repair is not recommended. When forks get broken or damaged, the best thing to do is replace them with new forks in the correct capacity for the model. Never try to weld or modify the forks for repair or adjust the use of the forks, The heat causes the forks to appear normal; however, there is undetectable damage from the heat.

For assistance with your forks, any forklift part or service, contact Shoppa's Mid America today!