Safety and ergonomics deliver fast payback
Toyota Motor Manufacturing looks within to meet high throughput demands.
By Staff -- Modern Materials Handling, 10/2/2005
One of the largest in Toyota's global network of manufacturing facilities is the giant automobile and engine plant in Georgetown, Ky. The facility, known as Toyota Motor Manufacturing Kentucky (TMMK), has 7.92 million square feet of production and office space under its roof at a 1,300-acre site where Toyota has invested a total of $5.3 billion.
TMMK looked to its sister company to supply a lift truck that was first, safe and comfortable to operate; and second, gets the job done efficiently. Following a list of suggestions from plant associates, the plant chose over 280 lift trucks to fit the bill.
Rick Noe, project manager for TMMK, conservatively expects a full cost payback from the new fleet in three years. Over 10 years he expects to save $8 million. Savings are due to many of the innovations in the lift trucks with an emphasis on safety and ergonomics.
Ergonomic features include a 20-degree swivel seat option to alleviate neck pain due to backward driving. The weight of the seat hood on electric lift trucks was reduced, so lifting the hood to change the battery is easier. Next, a hood lift assist was added, using a torsion bar with shock absorbers like those under a car's hood.
Operators noted that in loading soft-sided trailers from both sides, lift truck headlights tended to blind drivers on the opposite sides, so dimmer switches were designed into new lift trucks. Next, a horn button was installed on lift truck arm rests so drivers can sound the warning while in reverse without using their elbows, which had created strains and fatigue.
To accommodate shorter lift truck operators, team members recommended adjustable pedals to replace the foam blocks that operators were attaching to accelerator and brake pedals. Now, lift trucks are available with optional adjustable pedals. The result: better safety and operator comfort.
Currently in its implementation phase, TMMK has begun integrating the Wireless Asset Net system. The system will help to ensure compliance with vehicle safety regulations and enhance fleet management by providing vehicle locator capabilities, automated electronic vehicle inspection checklists, and impact sensors to establish driver accountability and reduce the costs of abusive driving.
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