Japanese titan Toyota embraces a ‘zero muda’ (no waste) lean philosophy that aims to eliminate the unnecessary consumption of time, money or effort. It extends to the Toyota Materials Handling business, which took visitors to IMHX Birmingham, including David Priestman, on a journey through six distinct zones that showcased a full-service provision.
With a firm commitment to net zero carbon neutrality by 2041, Toyota Materials Handling (TMH) puts ESG at the heart of its manufacturing and delivery. One process in achieving that is the usage of ‘zero carbon’ steel at its Swedish factories. This is recycled steel that is recovered, processed and then re-melted for use in forklift and warehouse vehicle production. The plants run on renewable energy including hydrogen and Ecovadis certification recognition has been achieved as a result.
Safety is paramount in the forklift industry, to protect workers and minimise accidents. TMH aim for continuous improvement in this area – a concept derived from the kaizen (good change) concept and method pioneered by Japanese producers. One example of progress are the new ‘BT Levio’ low-lifter powered pallet trucks, 1.3t to 2.0t. Available with lithium-ion or lead-acid battery, the trucks are equipped with cameras that provide surround sensing. It will automatically stop if it drifts towards someone’s leg, for instance. Audible alarms will sound when there is a risk of contact, and the cameras assist with the Levio’s ‘curve control’ turning.
Waste not, want not
On the energy front, ‘BT Reflex’ reach truck models now come with hydrogen fuel cell variants, with which the only by-product is water. The fuel cell system consists of the fuel cell stack, the 350-bar hydrogen tank, a small lithium-ion battery to temporarily store surplus energy, and a fan. All this is contained in a cast frame the size of a classic lead-acid battery and can be installed relatively easily in a conventional electric forklift.
Inside the fuel cell stack, the hydrogen is mixed with air, where it reacts with the oxygen in the air to produce water. During this chemical reaction, electrical energy is released; this energy is collected and used to drive the electric motors that power the forklift’s propulsion, lift and tilt systems. Suitable for pallet stacking up to 13m, block stacking, drive-in racking, outdoor use and operating in cold storage facilities, Reflex load capacities range from 1.2 up to 2.5 tonnes.
Connectivity and data and provided through the ‘My Toyota’ fleet management system. This details service levels, safety and telematics data, for example on usage and ‘shock’ incidents. Real time location, precise to 3cm, is achieved via AI cameras and mapping of the warehouse facility, including pallet locations.
Within the TMH group, mobile automation solutions including AMRs, order picking and automated mini-load storage are offered by the former Viastore Systems business in Europe (acquired in 2022), and by Bastian Solutions (acquired in 2017) in North America, as well as shuttles and automated pallet carriers. Automated reach trucks can work up to 12m high, can operate double-deep pallet storage and are provided on a rental basis only, enabling scaling up or down when required. Automated and manual warehouse vehicles are assembled on the same production line and engineers are trained to service and support either type.
Finally on the tour I was able to speak to Noel Blake from Vanderlande UK. Also part of the TMH global group, Vanderlande is branded by TMH UK as Toyota Automated Logistics, offering turnkey systems integration for fixed automation, conveying and sortation, including as a reseller of the AutoStore ASRS. I questioned why Vanderlande sells this product and the answer inevitably is, “why reinvent the wheel.”
But will the famous orange brand survive in the long term? I was unable to get a definitive answer, but we at Logistics Business are on-record for being sceptical of mergers and acquisitions as they often diminish competition, which is a waste after all.
