10 Ways to Reduce Forklift Maintenance Costs

Sometimes it’s easy to tell when to upgrade equipment. For example, an aerial lift or electric tug may stop working altogether and need to be replaced. But other times, it can be harder to tell if an upgrade is necessary. So here are some common telltales that it’s time for an update:

A warehouse can be filled with safety hazards which, if left unchecked, can cause serious harm to your employees or visitors.

4. You’re having difficulty tracking stock. This may be a sign that your current inventory tracking system isn’t sufficient. You may need to update your inventory software to help future-proof your business.

5. You’re unable to implement new technology. Working technology is essential to a well-functioning warehouse. At times, you may need to upgrade to faster internet or make electrical upgrades to run the software or tools you need to keep your warehouse operating optimally.

6. There’s not enough space. As your business grows, you may find that there’s no longer enough space in your warehouse to store inventory like returns. This calls for adding more space or upgrading to a modern racking system that is more space efficient.

7. Your dock is getting blocked up. If your loading dock starts having scheduling issues or you notice an increase in worker accidents or delivery slowing down, it may be time to upgrade to new scheduling software.

8. Overall productivity is decreasing. Sometimes overall productivity at your business may start to fall. This could happen for a variety of reasons, but one reason might be your warehouse equipment. For example, you may need to rearrange pathways or get a new tracking system.

Did you know that most forklifts can get up to a max speed of 10 MPH? That may not sound very fast, but it’s more than enough speed for a tragic accident. Someone could end up hurt or worse, and your business could suffer costly damage to machinery, supplies, and infrastructure.

In this article, we’ll go over why forklift speed matters. Specifically, we’ll cover official regulations, why it’s important to set your own speed limits, how to set them, and more.

You may be surprised to learn that, according to the Occupational Safety and Health Administration (OSHA), “OSHA does not have specific speed limits set for the safe operation of a powered industrial truck.” That said, OSHA does have regulations for how forklifts should be operated. These include the following:

Furthermore, there are industry standards that you may want to follow. For example, the Material Handling Equipment Distributors Association suggests a “maximum allowable speed of a forklift truck is 8 mph, but in areas where pedestrians move about, the forklift should not move faster than 3 mph.”

Just because there’s not an official forklift speed limit doesn’t mean you shouldn’t set your own. Forklifts can weigh anywhere from 3,000 to 20,000 pounds. Even at low speeds, they carry a lot of force and momentum.

On a similar note, forklifts can require a lot of stopping distance. At 4 MPH, the average forklift needs over 17 feet to come to a full stop. At 8 MPH, it needs 42 feet. Of course, this will vary between machines, so use a calculator to find out how much stopping distance is needed.

Failure to take these factors in mind increases the risk of safety hazards. For one, you could hit people, equipment, or infrastructure. In fact, workers getting hit by forklifts is one of the top causes of lift-truck-related work injuries. When you speed, you risk losing control of the vehicle, not seeing obstacles in time, and tipping over.

This can not only result in tragic accidents but costly fines, penalties, and losses. For example, you may be required to pay OSHA fines, incur expensive medical and legal bills, suffer costly downtime, and damage your reputation among employees and customers.

Setting a forklift speed limit is a balancing act. You want to prioritize safety, but you also want to meet your production goals. Often, the two work against each other. The faster you drive, the faster you can work, but the more dangerous the work becomes.

Our recommendation is to err on the side of caution. It’s better to take things slow than to risk a serious accident that could lead to someone getting hurt or worse and put you behind schedule.

When setting your speed limit, here are some things to consider:

The simplest way you can slow forklift speeds is to properly train operators. This should teach how to drive slowly and with caution, use your horn to alert others of your position, check your blind posts, keep a reasonable stopping distance, maintain a clear view, carry loads low to the ground, and obey traffic laws when driving on regular roads. You can develop an in-house program or outsource it to a professional

Once you have forklift speed regulations in place, you need to enforce them by warning and disciplining noncompliant operators. Of course, there are ways you can be encouraging, too. For example, you could set up speed limit signs across the warehouse, even radar ones that flash “slow down” when passing forklifts exceed the speed limit.

You can apply physical impairments, like speed bumps, or even install mechanical or electronic forklift speed controls. These devices force forklifts to stay under a custom speed limit that you set.

Whatever you do, make forklift safety a priority across the company so everyone knows what’s expected.

According to Fortune Business Insights, the global market for forklift trucks was 1.4 million units in 2021 and is projected to reach 1.9 million units in 2028, growing at a compound annual growth rate (CAGR) of 4.3%.

Warehouses use forklifts to move stock, businesses use them to load and unload cargo trucks, and retailers use them to pick orders. And, as the world increasingly adopts ecommerce, the need for forklifts will continue to grow.

However, with all the benefits that forklifts bring to businesses come some risks. If used incorrectly, forklifts can lead to serious consequences.

Fortunately, such accidents can be avoided. Keep reading to learn how much weight a forklift can handle, the risks to equipment and stock of overloading a forklift, the potential injuries caused by overloaded forklifts, and what to do if a forklift tips over.

The necessity of forklift safety isn’t necessarily the easiest to understand. That’s why many warehouses struggle to draw a line between productive shortcuts and recommended best practices, asking questions like:

Forklifts vary widely in their load capacity. On the low end, some forklifts can carry only up to about 3,000 lbs. On the high end, some forklifts can hold up to over 50,000 lbs.

As a forklift driver, it’s your job to know your forklift’s load capacity and stick to it.

Once you’ve established how much your forklift can lift, ensure that your load is under the limit. You can usually do this by reading the load’s label. If not, you may need to manually weigh it with a scale. Most forklifts have a scale built into them so you can quickly detect if a load is too heavy.

Whatever you do, don’t make guesses about the weight. It’s always better to double check to ensure you don’t overburden the forklift.

Why? Forklifts operate under a counterbalance system. The weight of the truck on the rear axle typically offsets whatever the weight of the carried load is. If the forklift is off balance because the carried load is too heavy, there’s a risk it will tip over and injure the driver or other workers and cause damage to the forklift and load.

Ready to up your weight capacity with a new forklift? HTX is Texas’s leading provider of forklift equipment, offering a wide selection from top manufacturers.

Here’s how your stock or forklift could get damaged through overloading:

If the load is fragile and hits the ground hard enough under all its own weight, it could get ruined. The same goes for the forklift. It could tip over and land on its side or back, which could cause serious damage to the machine.

Both scenarios could lead to expensive losses and repairs, which would ultimately hurt your bottom line.

Worse than damaged goods or machines are forklift injuries and fatalities. According to the National Safety Council (NSC), forklifts were the source of 7,290 nonfatal injuries in 2020. Here are the main ways that people end up hurt by overloaded forklifts:

1. Being inside a forklift that tips over: If an overloaded forklift flips over while you’re in it, you could end up seriously hurt by the fall, stuck inside the machine, or worst of all, crushed between the forklift and the ground.

To prevent this from happening, always wear a seatbelt, avoid tilting the forklift too far forward or backward, use extreme caution on inclines and ramps, avoid sharp turns, and drive slowly.

2. Getting hit by a forklift: Another way an overloaded forklift could hurt or kill someone is by hitting them. That is, the impact of the heavy forklift running into another worker could lead to injury.

To prevent hitting anyone with the forklift, try not to drive near other workers, follow designated driving routes, obey all safety rules such as speed limits and traffic signs, sound your horn to alert others where you are, and look both ways at intersections.

3. Getting crushed or run over by a forklift: Most forklifts weigh several thousand pounds. As a result, one of the most common causes of forklift deaths is getting crushed by one.

To help prevent this from happening, always wear a seatbelt, never allow workers to ride on the forks or on top of the forklift, stay inside of the operator’s compartment at all times while driving, and always check the route for hazards.

At the end of the day, overloaded forklifts are an unnecessary cause of injury and death. What makes forklift accidents especially tragic is that they are avoidable.

So, don’t let your forklift drivers make reckless mistakes. Train them well and make forklift safety a top priority for your business.

Did the delicate balancing act between your forklift’s weight capacity and your ambition fall through? Don’t panic. While you may be tempted to jump out of the vehicle, this may not be the best response since you don’t know how the forklift will land. Instead, remain calm and keep your hands firmly on the wheel. Try to position yourself in the opposite direction of the fall and brace yourself for impact. As soon as the forklift has completely fallen over, call for help.

Hopefully, you’re able to exit the vehicle safely and you can report the accident to your supervisors. Otherwise, get emergency responders on the scene as soon as possible and first aid if needed.

Lift trucks can be extremely useful. They can help you transport heavy loads to and from loading docks, storage areas, retail floors, work sites, and more.

But this equipment can also be dangerous, especially outside, as forklift operators need to stay cautious of potential hazards.

In this article, we’ll go over eight tips on how to safely operate a forklift outdoors.

Let’s get started.

Before you operate a forklift outside, it’s important to check the weather forecast. If the weather looks bad (or is expected to get worse), you may want to rethink operating a forklift.

Rain and snow can make the ground slippery or muddy, and fog could make it difficult to see. In some cases, a storm could even damage the forklift, and seasonal factors could impact the forklift’s ability to operate at all.

So, try to schedule the forklift job for when the weather is clear. That might mean postponing the task. Just remember that it’s better to be safe than sorry.

Next, it’s important to make sure you are using the proper gear and equipment.

If the weather is cold, wear warm clothing like a coat, gloves, and a hat. If there’s a lot of sunlight, be sure to wear some sunscreen. And you should always wear protective gear like a reflective vest and helmet.

As for equipment, make sure you have the right forklift for the job. It should be able to handle rough terrain. So you may need to weatherize it by equipping it with all-season tires, for example. Check out our lift trucks page to explore some of our outdoor forklifts for sale and rent.

Any time you get into a forklift, you should inspect it. Here are some things to check:

Other items to check include screens, lights, hydraulics, steering, and other attachments. Do all of this before you start driving the forklift.

When loading an outdoor forklift, make sure the load is stable so that it doesn’t fall over. For example, you don’t want to overload the forklift. Check its weight capacity and stick to it. You also don’t want to carry an off-center load. Stack crates and boxes evenly. And lastly, avoid carrying damaged or loose loads, which are at a higher risk of falling off as well.

While operating the forklift outside, the number one safety rule is to stay alert.

This means staying focused on the job at hand by eliminating distractions, constantly checking your surroundings, and keeping an eye out for other workers, obstacles, and even wildlife.

Driving a forklift outside is different from driving one inside because you aren’t in a contained environment. You need to stay alert to manage the increased risks. Anything could happen.

Operating forklifts is a dangerous job, not immune to safety hazards. Which, if left unchecked, can cause serious damages. Luckily, a safety checklist helps keep your workplace incident free.

One big difference between indoor and outdoor forklift driving is the terrain. Outside, you may face unsmooth surfaces (e.g. gravel and rocks) and more inclines and declines (e.g. hills and ramps).

As a result, you need to monitor the terrain. Watch for uneven surfaces, slopes, and gaps so you don’t slide or tip over the forklift. That way, you lower the risk of seriously injuring yourself and others and causing damage to the forklift or other equipment.

Keep in mind that the terrain could also change suddenly. For example, in transition areas between indoor and outdoor environments, there may be sudden changes in surface (e.g. smooth to rough) and even lighting (e.g. light to dark).

Learn how to navigate these tricky areas by practicing driving in them. Train yourself to slow down and carefully maneuver the forklift so you don’t run into any problems.

Communication is vital in forklift driving, especially outside. It allows you to alert fellow workers about your forklift position, driving direction, changing conditions, and sudden hazards.Forklifts are heavy pieces of equipment, after all.

By communicating with other workers while you drive, you can lower the risk of a job site accident and avoid serious damage or injury. Others can help you drive a forklift safely by communicating with you as well.

For example, they might watch your blind spot for you or give you a heads-up about an obstacle in your way.

Ultimately, great communication is the key to keeping everyone safe around outdoor forklifts.

One last, often neglected step of safe outdoor forklift driving is keeping your forklift properly maintained. Regular maintenance is especially critical for outdoor forklifts because they are more susceptible to the elements, leading to faster wear and tear.

So maintain a regular maintenance schedule for your outdoor forklifts. Clean them often to prevent rust, oxidation, and damage from salt exposure. You may also want to check the hydraulics occasionally and attend to any engine or warning lights. Doing so helps ensure your outdoor forklift stays in working order and lasts longer.

HTX Material Handling is Texas’s leading provider of lift trucks, parts, rentals, and more. If you need a durable, strong outdoor forklift to withstand an even tougher workspace, HTX Material Handling can help.

 As a business owner, you can’t afford to make many mistakes at the receiving stage because this will lead to issues downstream, such as stock control issues, higher operational costs, and faulty orders delivered to customers.

That’s why it’s important to handle inventory right from the moment a shipment arrives. In this article, we’ll go over how to do just that.

Here are six ways to better improve your warehouse receiving process:

To set your business up for success, you first need to determine what metrics to measure to evaluate warehouse worker performance, detect bottlenecks, and make improvements over time.

Some common key performance indicators (KPIs) that you should consider tracking include:

By keeping track of metrics such as these, you can see how well your receiving team is performing and where it can improve.

Before you make inventory orders, it’s important to establish pre-receiving requirements for suppliers and shippers to follow.

For example, you may want shippers to load the cargo in reverse order of the delivery schedule so that your receiving team can immediately put away inventory as they unload it. This way, they don’t have to sort through it first, leading to a more efficient system.

Another pre-receiving requirement you should have is a well-defined labeling structure. You may have specific requirements for what information is included on labels and where they are positioned on packages.

Just be sure to provide shippers all the proper documentation for labels upfront, and double check it to ensure it’s accurate. Do this in advance so that the receiving process runs smoothly later.

You may also want to define the number of packages allowed per pallet, the number of items allowed per carton, and an acceptable package size and weight range.

When it’s time to receive the inventory, you can then use barcoding, RFID scanners, and other technologies to quickly scan labels and see the content and quantity of what you are receiving.

In order to handle warehouse receiving and incoming inventory, you need to staff appropriately. Labor may be your largest warehouse operating expense, but it’s not something you can afford to skimp on.

Be sure to align worker schedules with the receiving schedules so that you always have enough staff on-site to receive deliveries. Being understaffed will only hurt your business operations in the long run.

Once you’ve received an inventory order, take an exact product count. You can use an inventory scanner system to help automate this process.

Then, open every package and perform a thorough inspection. Check the overall conditions of products. Look for broken seals, lost items, damaged products, mismatches in product SKU, and other discrepancies.

Inspecting inventory is an essential aspect of warehouse receiving, as it helps ensure faulty products don’t reach your customers. Don’t let the inventory clerk sign off on a shipment until they’ve had all packages checked and rechecked. If there are any concerns or questions regarding the shipment, the inventory clerk should voice them.

When it comes to actually putting away inventory, you need to make sure you have a team equipped to do some heavy lifting. This means they should not only have the physical strength to carry heavy loads but the right machinery.

Here at HTX Material Handling, we offer several types of receiving and handling equipment to help you work faster. From forklifts and lift trucks to electrical tugs, and more, we’ve got what you need.

Your warehouse receiving team needs to have a system for filling and storing products in an efficient way.

For example, you might have them store inventory on palettes, on shelves, or in bins. Whatever the case may be, make sure it’s a cost-efficient use of space that helps you save on carrying expenses.

One way to optimize your filing and storing system is to digitize it with software. The right software system can help direct putaway routes and ensure you maintain a FEFO (first expired, first out) sequence.

Finally, it’s important to maintain a robust inventory replenishment system. Replenishment orders should process automatically, as inventory gets low and undercounts are detected in a shipment. That way, you can streamline the warehouse receiving procces an replace products quickly, meaning they’re less likely to be out of stock when you need them.

After all, you never want your customers to suffer as a result of an inventory mistake (e.g., by having to wait for a backorder or by not being able to order at all). Instead, you want to take a proactive approach to prevent such issues in the first place.

Warehouse receiving isn’t a piece of cake. It takes an entire team dedicated to optimizing processes and always improving. Start small and learn as you go.

At the end of the day, any practice that can help you streamline receiving will help increase your bottom line. How? By boosting productivity and lowering operational costs.

If you’re ready to take your receiving process to the next level, consider getting more efficient equipment as part of your plan. Feel free to reach out to us today to discuss your needs. We look forward to chatting!

Electric tuggers are quickly becoming the go-to solution for efficient material handling. But with an array of options available, selecting the right one for your specific needs can feel like a challenge. In this blog, we’ll equip you with all the knowledge you need to make an informed decision and enhance your operations.

Ever wished there was an easier way to move heavy loads around your workplace? With an electric tugger, there is! Also known by names like electric tow trucks or industrial tuggers, these are battery-powered machines designed to effortlessly tow and maneuver wheeled loads.

Imagine a powerful, compact electric vehicle specifically built to pull carts, trailers, and other equipment. That’s the essence of an electric tugger. They bridge the gap between manual labor and heavy-duty forklifts, providing a safe and efficient solution for various tasks.

The core functionality of these machines is deceptively simple. Here’s a quick breakdown of how they work:

Electric tuggers offer a multitude of advantages that can transform your workplace. Let’s explore the benefits that make electric tuggers a winning investment.

Manual handling of heavy loads is a leading cause of workplace injuries. Electric tuggers eliminate this risk by taking the strain off workers. They safely tow and maneuver heavy objects, reducing the potential for muscle strain, back injuries, and repetitive stress disorders.

Time is money, and electric tuggers help you save both. They expedite material movement by effortlessly transporting loads, reducing turnaround times, and keeping operations flowing smoothly. Imagine the time saved compared to manually pushing or pulling heavy carts and pallets!

Electric tuggers free up your workforce to focus on higher-value tasks. Instead of expending energy on manual labor, employees can devote their time to tasks that require skill and expertise. This improves overall productivity and can even boost employee morale and job satisfaction.

Electric tuggers are powered by batteries, eliminating harmful emissions and noise pollution typically associated with gas-powered machinery. This not only creates a cleaner and healthier work environment but also demonstrates your commitment to sustainability.

While electric tuggers offer significant benefits, they come at a fraction of the cost of powered industrial trucks, i.e. forklifts. Their lower maintenance requirements and energy efficiency further enhance their cost-effectiveness, making them a smart financial decision for businesses of all sizes.

Looking to improve operations without breaking the bank? Discover how used equipment solutions from HTX Material Handling can help!

Electric tuggers are no longer niche machines. Instead, they’ve become the go-to solution for efficient, fork-free material handling across a wide range of industries. Their ability to effortlessly tow and maneuver heavy loads translates into improved productivity, reduced strain on workers, and a safer work environment.

Let’s take a look at some of the common applications of electric tuggers and the specific tasks they excel at.

Imagine a bustling manufacturing facility where raw materials, parts, and finished goods constantly move between workstations. Electric tuggers can play a crucial role in this fast-paced environment. They efficiently:

By eliminating the need for manual handling of heavy loads, electric tuggers ensure a smooth flow of materials, keeping production lines running efficiently.

Warehouses thrive on efficient movement of goods. Electric tuggers are perfectly suited for the dynamic environment of a warehouse, helping to:

Electric tuggers maximize storage space utilization by allowing for narrower aisles and efficient maneuvering around corners. This translates into faster retrieval times and improved overall warehouse productivity.

Construction sites are inherently demanding environments. Workers constantly move a variety of heavy materials, tools, and equipment. Electric tuggers can significantly improve efficiency and safety on these job sites by:

The compact size and maneuverability of electric tuggers make them ideal for navigating uneven tight spaces often found in manufacturing environments and warehousing. Additionally, by reducing manual strain associated with moving heavy objects, electric tuggers help prevent worker injuries and fatigue.

Large retail stores deal with a constant flow of merchandise. Electric tuggers can significantly enhance efficiency in these environments by:

Electric tuggers help maintain a clean and organized shopping environment, improving customer satisfaction and staff productivity. Their compact size allows for easy navigation through busy aisles, ensuring smooth and efficient stock movement.

Now that you have a better understanding of electric tuggers, you might be wondering which brand to choose. At HTX Material Handling, we recommend that you look no further than MasterMover®.

With a rich history of delivering top-notch equipment, MasterMover® has earned its reputation as a reliable partner for businesses seeking excellence in their operations. As a leading innovator and manufacturer of premium electric tuggers, they offer:

Investing in a MasterMover® electric tugger is more than just acquiring a machine. In reality, it’s a strategic decision that pays off in the long run. When you purchase these machines, you can unlock a new level of efficiency, safety, and productivity in your workplace.

Ready to transform your material handling operations? HTX Material Handling offers a wide range of MasterMover® models to perfectly match your specific needs. From light-duty applications to heavy-duty industrial environments, we can help you do it all.

Contact HTX today and discover how MasterMover® electric tuggers can revolutionize your workplace!

Determining which type of tugger is best for your warehouse or material handling environment doesn’t need to be a challenge. Here are a few tips to help you determine which will work best for your operations.

At the end of the day, the choice is up to you. Do your due diligence and you’ll be able to find the right electric tugger for you in no time. Feel free to reach out to us if you have any questions!

Forklift owners have a duty to maintain their equipment. Failing to do so could lead to costly malfunctions, unsafe work environments, and trouble with government regulators.

That said, forklift servicing and maintenance can get expensive fast. If forklift maintenance is eating away at your profit margins, keep reading to discover 10 ways to reduce maintenance costs.

A forklift can do a lot of damage if not operated properly. For example, it could collide with other property, damaging itself and other equipment. On top of that, the long-term effects of poor forklift driving can lead to more wear and tear, which also ramps up forklift maintenance costs.

This makes it important to train forklift operators on how to use the machine properly. To do this, you can conduct regular training and ensure your workers get OSHA certified.

Another way to lower forklift maintenance costs is to perform daily inspections before each use.

First, inspect the forklift visually by checking the wheels, seat belt, oil and gas levels (or battery level if electric), and other visible components. Then inspect the forklift operationally. Does the engine turn on? Do the lights, signals, wipers, horn, transmission, brakes, steering, and exhaust system all work as designed?

If so, the forklift is probably ready for use. If not, get it checked out first. Ignoring maintenance issues may lead to costly repairs later on.

Keeping the floors at work in good shape helps keep forklift maintenance costs down.

Bad floors can wear out the forklift faster. For example, if the floors have holes, uneven surfaces, debris, or other hazards, they will take a bigger toll on the forklift’s tires.

It pays to keep your work floors smooth and unobstructed as much as possible.

In addition, performing regular forklift maintenance may help lower your maintenance costs. This is because neglecting maintenance or doing it irregularly tends to lead to costly repairs and even equipment replacements.

For example, if you never change your forklift’s oil, you could end up ruining the engine, which costs much more to replace than it costs to perform regular oil changes.

You may also want to check and replace a forklift’s tires so you don’t accidentally end up damaging the wheels (especially since forklifts don’t have suspension).

Set up a forklift maintenance schedule and keep to it. A little preventative maintenance can save you a lot of money in the long run.

When it comes to repairs, you can save a lot of money by doing them in-house. A professional forklift mechanic may charge high prices for their services.

If it can be a small DIY repair, let it be. There’s no need to outsource what you can do yourself. Just make sure you actually know what you’re doing.

For example, if you need to replace a light on the forklift, verify what size bulb you need before you go out and buy a replacement. If you’re unsure how to swap out the old one for the new, look up instructions online.

Regular forklift cleaning is a great way to reduce wear and tear on your equipment. Explore our blog to learn more about how you keep your machine in good working order.

That said, some repairs are too big to handle on your own. In that case, it’s actually cheaper to hire professional help.If you try to fix something on your own, you may create further damage. In other words, you may do more harm than good.

For example, if the forklift’s transmission needs to be replaced, hiring a professional mechanic to fix it is probably the best maintenance strategy. Don’t create more maintenance costs by trying to skimp on needed repairs. Sometimes, hiring a professional is more cost effective.

There are many different forklift brands out there. But to save on maintenance costs, it helps to limit your forklifts to one or two manufacturers. This way, you don’t have to deal with many different companies for parts and you don’t need to train your workers how to operate different models of forklifts.

Do your research, choose a forklift manufacturer you like, and try to stick with them. Your forklifts will be much easier to manage and maintain that way.

Not every job requires a forklift, and if you use a forklift anyway, it may not be good for the machine. The improper use of a forklift will then lead to higher maintenance costs.

Instead of trying to do everything with a forklift, own different machines for different tasks. It may cost more upfront, but it’s worth it in the long run. Always try to match the truck to the job.

You may also consider investing in electric forklifts. They require no gas and are much easier and cheaper to maintain as a result.

Though electric forklifts may be more expensive than gas-powered ones, the long-term savings make them well worth the investment.

If you get an electric forklift, try to get one that uses lithium-ion batteries instead of lead acid ones. They require less upkeep and are less likely to overcharge.