Forklift Maintenance Best Practices and Tips and Tricks

Jul 18, 2019

Forklift Maintenance Best Practices

Forklift Maintenance Best Practices. There’s no doubt that warehouse management strategies come in all shapes and sizes, but one thing that’s universal is a comprehensive approach to equipment maintenance — and that’s non-negotiable.

Of all the equipment used in a manufacturing facility or warehouse on a daily basis, the forklift is probably the one that is depended on the most to keep things flowing and moving efficiently and safely. Think about this: What would happen to your supply chain if suddenly your warehouse forklifts were out of order?

Why is Forklift Maintenance So Important?

Safety, efficiency, and optimization are all great reasons to maintain your forklift, but it’s also important to remember that a new forklift is a big investment and one that needs to be protected from unnecessary wear and tear.

Below our forklift pros layout best practices and maintenance tips that can help keep your forklift — and your warehouse — running smoothly.

 

 

Create a comprehensive forklift inspection checklist and follow it — no exceptions

Even forklifts that are being used every day can present with small problems that could get much bigger and more serious. On top of that, it’s an OSHA requirement to ensure that everyone who uses every machine is safe every day.

While OSHA provides a comprehensive guide for these checks, it’s easy to customize for each unique warehouse situation. Regardless of what else you add to your list, make sure it includes inspecting hoses, tires, seat belts, fluid levels, forks, guards, and brakes.

Don’t ignore the forklift manufacturer’s guidelines; they exist for a reason

Whichever model, make, or brand of forklift you choose to invest in will come with clear maintenance guidelines, and it’s important to follow them on schedule. Note the usage benchmarks and follow them — 100 hours of usage means 100 hours of usage.

Knowing that these tasks are completed to the specifications keeps machines running and helps for budgeting the time and cost expense of downtime for maintenance services. It can also eliminate potential issues during troubleshooting.

Taking your tires for granted could be a huge mistake

Forklifts travel miles each day, so it’s not surprising that wear and tear can happen quickly with the repetitive motion of the back-and-forth. Tread loss, leaks, and deflation are also signs that tires may need to be replaced or refilled.

Not only could tires in poor condition cause the forklift to malfunction, it can also cause damage to warehouse floors. This increases facility maintenance costs along with downtime as the floors need to be repaired more frequently, and create unsafe situations for everyone.

Making tire checks a part of daily inspections will help ensure little problems don’t get bigger over time. Remember that OSHA mandates forklifts to be taken off the warehouse floor for missing pieces of tire rubber. Be sure to replace tires regularly just like you would on any other vehicle you use often.

 

 

Cleaning forklifts needs to be a part of any comprehensive maintenance plan

It may not matter much to some forklift operators if their machine is dirty or dusty, but the debris that settles on machines could end up being combustible and cause much more serious malfunctioning of the radiator. It’s no secret that working in dirty conditions creates another layer of risk that warehouses must mitigate.

Although it’s never fun, weekly maintenance can go a long way in protecting everyone on the job. Blow out the radiator, wipe down the dirt, change filters — these are all steps that should be on your maintenance list. Regular cleaning can also reduce costly repairs and help operators avoid accidents.

Tackle any and all issues when they pop up

Despite the best planning and maintenance, you’re bound to run into the occasional problem that arises with your forklift. Small issues like soft breaks or bent forklift tines can turn into major issues that can disrupt work and even increase safety risk. Although this may go without saying, don’t wait to address these issues and certainly don’t ignore them.

Part of knowing which small issues to look for is encouraging employees to communicate with each other and managers about these problems. Noises, grinding, slipping — these are all signs that something needs to be taken care of before it gets much more dangerous.

 

 

Pick a warehouse management partner that can help

Before you even start making checklists and daily maintenance plans, it’s crucial to work with a team who knows the challenges and struggles you face every day. Experts can not only guide you through the forklift purchase process, but also provide support for service and repair and offer other warehouse management services.

Choosing Benco means your facility and equipment — from the floor of your warehouse to the roof — keeps your business running smoothly and your employees safe on the job. Our team of experts offers a large range of services that can optimize your warehouse for efficiency and safety. Get in touch today!

Common Hazards in Your Warehouse (And How to Avoid Them)

08 Apr, 2024
Warehouses are the backbone of many industries, storing and distributing goods to keep the economy moving. However, behind the scenes of this logistical hub lurk various hazards that can pose severe risks to employees and property. Let's investigate some of the most common warehouse hazards and explore proactive mitigation strategies. Slips/Trips/Falls Slips, trips, and falls are among the most prevalent hazards in warehouse spaces. Spills, cluttered aisles, and uneven surfaces can easily lead to accidents if not adequately addressed. To prevent such incidents, warehouses should prioritize proper housekeeping, including regular cleaning and maintenance of floors. Additionally, using signage to highlight potential hazards and ensuring adequate lighting throughout the facility can significantly reduce the risk of slips, trips, and falls. Fires Flammable materials and electrical equipment in warehouses make them susceptible to fires. Faulty wiring, improper storage of combustible materials, and lack of fire suppression systems can all contribute to the risk of fire outbreaks. Implementing preventive measures such as regular equipment maintenance, proper storage protocols for flammable materials, and employee training on fire safety procedures are crucial in mitigating this hazard. Harmful Substances Warehouses often house various chemicals and hazardous substances, which can pose risks to employees' health if not handled properly. Exposure to harmful substances can lead to respiratory issues, skin irritation, and other serious health problems. To mitigate this hazard, warehouses should properly store and label hazardous materials, provide employees with appropriate personal protective equipment (PPE), ensure adequate ventilation systems, and conduct regular training on safe handling procedures. Falling Objects With shelves stacked high with merchandise, falling objects present a significant hazard in warehouses. Poorly secured storage systems, improper stacking of items, and inadequate safety measures can all increase the risk of objects falling and causing injury. Warehouses can minimize this risk by adequately securing shelves and storage systems, using barriers or guardrails to prevent objects from falling, and conducting regular inspections of overhead storage areas. Overexertion The physical demands of warehouse work can lead to overexertion injuries if employees lack adequate training or don't perform tasks ergonomically. Lifting heavy objects, repetitive motions, and working in awkward positions can all contribute to overexertion injuries such as strains and sprains. To prevent such injuries, warehouses should provide comprehensive training on proper lifting techniques, encourage the use of mechanical aids such as forklifts and pallet jacks, and implement ergonomic workstations to reduce strain on employees' bodies.

Common Inventory Management Mistakes

08 Mar, 2024
Effective inventory management practices influence the success of each warehouse, the supply chain, and the business at large. Inventory management involves many moving parts and elements – everything from the product catalog to the warehouse space to tracked KPIs. Experienced warehouse managers know that no matter how fool-proof your inventory management systems are, there’s always room to improve and prepare for unexpected circumstances. Let’s discuss common inventory management mistakes (and what to do instead). Overstocking or Understocking One of the most prevalent inventory management mistakes is maintaining too much or too little inventory. Overstocking ties up valuable capital and warehouse space, leading to increased carrying costs and a higher risk of obsolescence. On the other hand, understocking can result in stockouts, backorders, and dissatisfied customers. Businesses should leverage historical sales data, market trends, and advanced forecasting techniques to accurately predict demand and optimize inventory levels. Inaccurate Demand Forecasting Businesses are prone to making costly inventory planning errors without precise demand forecasting. Relying on outdated data or flawed forecasting methods can lead to inefficiencies and missed opportunities. By utilizing advanced analytics and predictive modeling, businesses can better anticipate shifts in demand, seasonal fluctuations, and emerging trends, allowing for more informed inventory decisions and improved responsiveness to customer needs. Lack of Inventory Visibility Poor visibility into inventory levels across multiple locations or channels can result in operational inefficiencies and errors. Without real-time data on stock levels and movement, businesses may struggle to fulfill orders on time, leading to customer dissatisfaction and lost sales. Implementing integrated inventory management systems that provide comprehensive visibility into inventory across the supply chain can help businesses optimize inventory allocation, reduce stockouts, and improve overall operational performance.

A Beginner’s Guide to Electric Forklifts

By Denis Benden • 08 Feb, 2024
Efficient material handling is crucial for businesses of all sizes and industries. It directly impacts productivity, cost-effectiveness, and overall operational success. Effective material handling ensures that goods are moved, stored, and transported in a streamlined and organized manner, minimizing delays, damages, and errors. Electric forklifts play a significant role in effective material handling, transforming the […] The post A Beginner’s Guide to Electric Forklifts appeared first on Benco Industrial Equipment.
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