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INDUSTRIAL
Forks in the Road
Lift Trucks: The Buying Decision
By Andrew Brooks
Supply chain management consultant Bard Critoph has seen some strange, scary sights while helping his industrial clients plan and improve their facilities.
"One operation had 'man-up' turret trucks, where the operator rides up on a platform with the forks," Critoph recalls. "Obviously the purpose of the units is to let the operator do picking from cases that are stored on high shelves. That's fine when you're dealing with small, light items, but what was being picked in this case was car batteries! The operators would ride up to the shelf, and because there's no way you're going to heft a car battery by just turning and reaching, they'd get partway off the platform and put one foot on the storage shelf while they loaded the pallet!"
But for Critoph, principal of Toronto-based Bard Critoph and Associates, such a situation goes beyond simple carelessness and points to a deeper problem - a failure to understand one's materials handling needs, poor facilities planning, a conscious decision to 'go cheap' and not pay what's required to get the right equipment, or a bit of all.
Although Critoph emphasizes the danger of doing things on the cheap, he may have his work cut out for him in getting that message across: according to a fork truck survey in the Jan./Feb. 2004 issue of Materials Management & Distribution, purchase price is among the top three buying considerations for 71 per cent of users surveyed, well ahead of other factors such as durability, safety and operating cost.
While operations staff generally handle the phases of the buying process that focus on what specific unit to acquire, it's the purchasers who look after the actual conduct of the transactions.
"Generally I find that they want to negotiate the lowest possible price," says Critoph. "But going cheap can be a mistake. For example, if you need a 24-foot lift height, you go for a unit with a lift height of an inch more than that. But the problem is that when you have a mast at full extension like that it starts to flex and the load becomes unstable, and so aside from possible serious accidents you can have operators simply unwilling to do the job."
Ergonomics, which also rates high on Critoph's list, scored a less than inspiring seventh-place finish in the MM&D survey (the category was given as "Operator Comfort"). But ergonomics, and efficiency in all of its forms, depends to a large extent on facilities planning. In the case of the poorly-placed car batteries, the problem could have been solved by moving such heavy items to a floor position where handling would have been easier. This in turn might have required shelving pallets two or three deep in the aisles. This in turn could mean a redesign of shelving throughout the facility, narrower aisles, and thus a different kind of fork truck for the greatest efficiency.
"It usually comes down to dollars," is how Critoph puts it. "You have to spend money to make money."
For more detailed information, see the MM&D forklift survey referred to above (www.mmdonline.com). MM&D also publishes a column by Dave Luton, who frequently discusses trends in the lift truck market.
Below and on page 30, we offer a quick roundup of some new and notable units on the market:
Nissan Platinum
At the beginning of this year Nissan Forklift announced its new Platinum series forklifts, Available in pneumatic, compact pneumatic and cushion tire formats, the Platinum Series has been designed around new technology and with a view to reducing exhaust emissions ahead of (and exceeding, Nissan says) new requirements established by the EPA in the U.S. for 2004 and beyond.
The key to upgraded emissions compliance is the new Electronic Concentrated Control System (ECM) on all Nissan K21, K25, gasoline, LPG and dual fuel industrial engines. The system controls basic engine functions and determines the exact air/fuel ratio, torque and speed needed for each particular application. A Vehicle Control Module (VCM) monitors a variety of sensors to improve engine and transmission control and the performance of safety features. The ECM and VCM systems provide data to the operator and maintenance personnel through an "Easi-View" meter panel. See www.forklift.toyota.ca for more details.
Toyota's Fingertips
The increased attention forklift makers are paying to ergonomics and operator comfort is typified by Toyota's introduction of the "Mini-Lever' fingertip control option.
Toyota says that the typical installation position for forklift control levers - on the cowl of the vehicle - prevents the operator from having to look away to operate the truck, but may result in fatigue or stress-related injuries. Toyota's solution is an option that incorporates miniature mast and fork controls into a padded four-way adjustable armrest.
The controls can be operated with only three fingers and allow for the same eyes-forward stance as cowl-mounted controls while eliminating the need to reach. A wire guard prevents accidental operation.
The optional control stack is available on most Toyota 7-Series lift trucks and integrates with Toyota's System of Active Stability (SAS). More details at www.toyota.ca.
Raymond 7400
Raymond has recently introduced the Model 7400 bi-directional "Reach-Fork" truck (pictured on opposite page). The 7400 incorporates Raymond's own "ACR" system, which combines AC technology and ergonomics to enhance efficiency and increase operator productivity while reducing costs. The 7400 is available in a variety of weight capacities, from 3,200 lb. to 4,500 lb., in Reach and "Deep-Reach" configurations.
Ergonomic features include:
- Universal Stack Stance" for more efficient true bi-directional travel;
- secondary control handle to improve user convenience and comfort during tractor-first travel;
- user-friendly control layout;
- roomy compartment to accommodate multiple working positions;
- contoured padding for weight relief and comfort;
- low step height to avoid unnecessary climbing.
The 7400 display panel provides real-time data, such as time, battery charge and weight on forks, on a large screen, and improves programmability. For cold conditions, the 7400 has an optional ThermaKit system with a heated control handle and heated floor cushion. For more information see www.Raymondcorp.com.
Mitsubishi "N Generation"
Mitsubishi has introduced a new series of forklifts rated at 3000 - 7000 lbs. capacity. Called the N Generation series, the pneumatic tire forklifts are designed to meet EPA emissions standards and address ergonomic issues as well as operating reliability and maintenance.
The N-Series units are powered by Gas/LPG and diesel engines. An automatic sensor system monitors oil pressure and coolant temperature, and kicks in to limit engine revs if either metric goes critical. An on-board diagnostic system stores error codes so maintenance staff can troubleshoot more easily and take more accurate corrective action. In addition, transmission and hydraulic systems will not operate if the operator isn't properly seated. For more, see www.mit-lift.com.
Hyster J-Series
Hyster's J45Z-J65Z Series sit-down, counterbalanced pneumatic lift trucks are powered by AC technology, which Hyster says provides the same performance of internal combustion (IC) units while reducing noise, eliminating exhaust emissions and providing a more comfortable ride.
AC motors function without motor brushes, commutators or contactors: the elimination of moving parts contributes to motor reliability, one of the chief attractions of AC units. The J-Series offers an optional brushless hoist motor, which reduces the time required for maintenance and leaves the operator more time behind the wheel.
The 80-volt electrical system lowers the truck's Amp requirements, resulting in lowered heat generation levels and longer component life. An "Extended Shift" function improves speed management and responsiveness while an in-dash display provides better motor control. Hyster Company's proprietary thermal system uses logic-tree CANbus communication technology and sensors to modify functions and accommodate temperature increases during continuous operation.
The J45Z-J65Z Series is rated at 4000-6500 lbs. Hyster also produces the E-Series AC forklifts, rated at 4500-6500 lbs., and the J30XMT2 - J40XMT2 three-wheelers at 3000-4000 lbs. For more information, see http://go.hysterusa.com/pr.
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