Developing to Match Customer Needs

Developing to Match Customer Needs

By Mark Faiman, Product Manager, Special Products, Toyota Material Handling, U.S.A., Inc.

In the daily routine of the typical facilities technician, there are many challenges to ensure the plant operates at top efficiency and equipment costs are kept minimal.  The last thing a technician needs to worry about is whether his/her tools and equipment are functioning properly or if he has the right equipment to do the job in a timely manner.

One challenge the technician faces is working on elevated items -- on walls, ceilings, or even on machinery. In the past, the tools of the trade have been an assortment of ladders or scaffolding, and part of the burden was spending time setting-up the product and ensuring that it was stable. It was time consuming.

The development of the electric scissor lift was the first big step in increasing the level of productivity for technicians by reducing the need for ladders and scaffolding, thereby allowing them to work quickly with a minimum of set-up time. This has led to the growing popularity of the electric scissor lift. Today it is common to see at least one to two scissor lifts onsite at medium and large-size facilities or to obtain a unit from a rental yard when needed. 

Expanding into New Markets

Aichi, a Toyota Industries Company, has a 40-year-plus legacy in the aerial work platform (AWP) industry.  And, when the company looked at the opportunity to expand the product line into the United States and European markets, product engineers realized the line of scissor lifts needed to be adjusted to meet the operational conditions specific for these markets, such as longer product run times, growing demand for electric vehicles to meet environmental requirements, etc.

Genchi Genbutsu – See for Yourself

Product engineers undertook what is known in the Toyota Production System as “Genchi Genbutsu” – which means to literally “go out and see for yourself” and promotes one-on-one interaction with customers to understand their daily needs and challenges. As part of this extensive review process, engineers visited scissor lift operators worldwide to gain feedback on a range of associated product issues from the basic specifications to finding the best angle to hold a control. The data compiled led the design and development process.

Responses gathered from customers revealed the opportunity to integrate new technology to help address operators’ top concerns including: 

• Reducing down time associated with the need to recharge batteries, and maintenance
• Increasing maneuverability in tight and awkward work locations
• Increasing functionality of items including slide out extensions and handrails

Maximum Productivity and Ease of Operation

With this information Aichi set forward with the design and development of the new SV-C Series of scissor lifts under the theme of “Maximum Productivity and Ease of Operation.”

The line-up developed consists of three main groups of machines:

• SV1530C / SV1930C 15-ft. or 19-ft. platform height, 30-inch wide units
• SV2032C / SV2632C 20-ft. or 26-ft. platform height, 32-inch wide units, and
• SV2646C / SV3246C 26-ft. or 32-ft. platform height, 46-inch wide units. 

This line-up covers the majority of the electric scissor lift applications found worldwide.

Meeting Operators’ Needs

Aichi is addressing lowering service costs and run time by integrating Toyota’s AC motor drive technology into the Aichi electric scissor lift line.  Aichi offers the industry’s only scissor lifts with AC technology.

In 2001, Toyota was the first major manufacturer to bring AC drive technology to the electric lift truck market. Today, every major electric lift truck manufacturer has followed Toyota’s lead and adopted AC drive technology.

A few of the ways this AC drive technology addresses concerns found during Aichi’s surveys include:

• Machine run time is increased and power consumption is decreased: due to the more efficient AC drive motors, allowing the operator to easily perform a full day’s work without recharging.
• Periodic maintenance work is decreased and down time is reduced:  due to elimination of components such as brushes in the motors, directional contactors, and removal of hydraulic drive systems and hosing. Components in the controller are reduced as well, making for a very compact drive controller.  In addition, the motors are mounted directly to the wheel hubs to reduce component counts in the machine and increase room in the chassis.
• Quieter operation of the equipment: the motor runs only when the drive is required and fully proportional control of the drive motors. A continuous operating, power-consuming hydraulic pump is not needed.

  An area that is quite often overlooked in this type of equipment is the productivity of the operator. This was addressed in several ways on the new SV-C Series units by addressing items such as the function of basic controls and elements of the machine. Examples include:

• Reducing the number of pins needed to lower the collapsible handrails  to four. Previously studied machines had up to 10 pins required to be removed. 
• Mounting the roll-out extension deck on large nylon rollers and nylon slides placed inside the hand rails to greatly reduce the effort required to extend or retract the extension. Some of the previously studied machines had metal-to-metal contact between the deck and the extension or very thin wear pads that required frequent replacement.
• Placing all of the lower controls for the machine in one control panel at the end of the unit protected within the chassis. An operator can perform all of the basic checks of the machine quickly and get to the job at hand. Competitive machines place controls behind panels, in exposed locations or in multiple locations, etc.
• Creating a more ergonomic layout for the control panel. The upper

controls feature an 8-foot long control cable, built-in hand grips, and a hanger to allow placement of the box on the collapsed rails to allow for moving the unit through a doorway or loading onto a trailer.

Automotive-Like Steering

To enhance productivity, Aichi developed an optional proportional steering system so the SV-C Series units steer like a car. The control box features a fingertip-sized steering wheel and automatic return-to-center for the steering system. This way the operator only has to make small corrections to adjust his steering, and he never forgets where the wheels are pointed.  Upon powering up the machine, the wheels are automatically reset to center to make sure the off-center condition does not occur.

With the research conducted and the above-listed features enhanced to meet customer’s needs, Aichi feels they have met their development target of “Maximum Productivity and Ease of Operation” to help scissor lift operators improve their work function.

About Aichi, A Toyota Industries Company:

Since its founding in 1962, Aichi has worked tirelessly to improve work environments in cooperation with its customers to create more efficient and comfortable work sites for industries such as the utility, communication and construction industries.

The company has worked closely with its customers to improve job site methods by creating more efficient equipment tailored to each industry. Toyota Aichi dealers offer industry-leading support in every area of service, including parts, maintenance, financing, rentals and accessories. For more information on Aichi products, please visit www.toyota-construction.com or call 1-800-852-0024.

About the Author:

Mark Faiman is a product manager, special products for Toyota Material Handling U.S.A., Inc. (TMHU). He is responsible for research and planning for aerial work platforms, tow tractors and other special products for TMHU.