As a Facility Manager, do you often find yourself searching for “Forklift repair near me”?

You are not alone. Forklift breakdown and replacement is a common event across the industry. On an average, MHE related expenses account for 19% of the total operational expenses.

The good news is – if handled with care and maintained properly, Forklifts can easily last for 8-10 years.

Here are some simple practices that need to be followed while using Forklifts. They would help you to avoid surprise forklift breakdowns and reduce the repair requirements by at least 65%.

Maintain a suitable floor surface for Forklift Operations

A damaged surface that is not leveled will lead to damage in forklifts. It also reduces the life of its battery and tires. For a forklift to have a long repair-free lifespan, it is important that the floor is well maintained.

The main features of a Forklift floor are –

It should be perfectly leveled To avoid a bumpy ride for the forklift

It should have an optimal frictional coefficient Too smooth will lead to slipping and too rough will lead to tire wear and low battery life

It should be hard enough (MOHS scale > 5.5) To withstand damage from metal forks. Epoxy is not hard enough and gets damaged by forklifts

It should remain unaffected by heat A Forklift slightly heats the floor while running. Epoxy becomes sticky when heated. It sticks to forklift tires leading to tire marks and Epoxy damage

For details on important floor features, read our article on: How to plan the perfect floor for Forklift Operations

Practice Predictive Maintenance to avoid surprises

Generally, the repair requirements in a Forklift follow a pattern.

There would be 2-3 major factors that cause forklift damage. As a Facility Manager, one needs to:

IDENTIFY – ANALYZE – ERADICATE these factors.

One also needs to identify the average time-span between the repair requirements.

Studying these two factors can help a facility manager to predict and prevent future forklift breakdowns.

Make sure that the Operating Guidelines and Limits Are Followed

The manual of a Forklift must ALWAYS be read thoroughly! The usage recommendations mentioned in the manual must be followed. This includes recommendations related to maximum load, Battery water, Fuel, etc. for the said forklift.

It is also important that the Drivers are well versed with these recommendations. Following them is important for the safety of both – the driver and the Forklift.

Here are a few suggestions to ensure that the drivers follow best practices of Forklift Operations:

Regular Training

Daily or Weekly Quiz on the best practices of Forklift Operations

Displaying the list of best practices in the driver’s cabin. Usage of pictures and easy language would be effective

Basic Checkup before and after each shift

The driver needs to do a basic checkup of the forklift before and after the shift.

A checkup before starting the shift ensures smooth operations throughout the day. Whereas, a checkup after ending the shift, where the driver checks fuel levels and other small factors, they wont have to waste their shift time – the next day.

Some of the major points that need to be check points here are:

Battery/ Fuel Level must be full

Battery Water should be at optimal level

Tire Treads are not faded

There are no loose Nuts and Bolts

There is no oil leakage

Store in a Clean and Dry environment

Forklifts are designed to work in an industrial environment. However, they don’t need to be kept in harsh conditions.

Factors such a dampness and moisture cause rust on forklift parts – which deteriorates its life.

Ensure that forklifts are kept in a covered area which is free of dampness, humidity, dust and spilled liquids.

If using an electrical forklift, arrangements need to be done for cleaning battery acid in the storage area.

Follow a regular maintenance schedule

When a Forklift part wears or breaks – it causes a chain reaction affecting multiple systems. It is important that even small wear and tear issues are checked and solved at regular intervals.

A maintenance calendar is of great help here. The facility management team needs to chalk out and follow a schedule for regular forklift maintenance.

Ideally, a Forklift maintenance/ service should be scheduled every 3 months or after 250 hours of operation (as per convenience).

A suggestive list of checkpoints for such a service schedule includes – regular greasing, Tightening Nuts and Bolts, Checking Hydraulic Lines, Checking Brakes and Steering Wheels etc.

Hope this article was useful. Let us know if you need more details or specific recommendations on your plant/ warehouse maintenance challenges. Write to us for free planning of your factory/ warehouse floor at info@rezovate.com. Our experts will be happy to help.