With some top-of-the-line models costing up to $100,000 a pop, it's obvious why you need to take good care of your lift trucks. But there's a lot more to it than an occasional lube job.
Funny how the very same people who wouldn't think of pushing their Integras to go 70,000 miles without an oil change, hauling loads of bricks in their Miatas or allowing a novice to grind up the gears on their new Touaregs behave almost casually when it comes to the welfare of their lift trucks. And it's all the funnier—or maybe not so funny—when you consider that those forklifts they treat so off-handedly cost anywhere from $15,000 to $100,000 apiece.
Maybe it's the forklift's reputation as the indestructible workhorse of the warehouse, maybe it's time pressure, maybe it's ignorance. Whatever the cause,that neglect invariably results in premature wear or even a smoking, screeching breakdown.
How can you protect your lift truck investment? Keeping the trucks in prime condition requires a three-pronged approach. First, you match the truck to the job; then you keep up with maintenance; and finally, you operate the trucks as directed by the manufacturer.
The match game
Step one in keeping your lift trucks in top operating condition takes place before the rubber hits the DC floor with the selection process. You have to match the t ruck with the specific job you need done. "Every application is unique in some way, shape or form," says Martin Boyd, manager of product planning at Toyota Material Handling U.S.A. Inc. of Irvine, Calif. " But choosing the right model is absolutely crucial in determining not only how productive the truck will be but also how efficient your overall operation will be."
Figuring out what features you want in a truck requires a lot more than just picking one from column A and two from column B. It's more a matter of sizing up your own operations, says Susan Comfort, marketing director, order-pickers and very narrow aisle products for The Raymond Corp. of Greene,N.Y. "When evaluating trucks for the job, you have to consider all the tasks the operator is required to do," she says. "You also have to consider the load—its weight, length, width, and the height it will be raised to. Then look at the warehouse layout—the aisles and rack staging area—and determine the amount of run time per shift for each truck." But looking at current requirements is not enough, she adds. "You also have to consider and anticipate any changes in the tasks, the loads, the work period and the warehouse."
That attention should extend to the lift-truck attachments and options, too. Pick the wrong fork for a hydraulic-shift truck, for example, and the operator will lose valuable time making up for the shortcoming. Putting a lift truck to work in a paper operation without fitting it with a special clamp to help maneuver paper rolls could make it nearly impossible to move the truck into tight spaces. And using a vehicle in a cold food storage environment without outfitting it with a "cold package" designed to help it adapt to a wide range of temperature variations will cause it to fail soon after driving out of a freezer as condensation builds up on the electronics. When shopping for lift trucks, make sure that you're working with reputable and well-informed dealers. "It's vitally important that your salesperson spend the time to understand how the truck will be used in your specific application," says Boyd. "The two biggest mistakes a lifttruck salesperson can make are to bypass the application survey stage and to base the configuration of the new equipment on old equipment presently being used."
All too often, DC managers ask their dealers to replace "exactly what they have," adds Jon Levine, vice president of counterbalanced product sales at Yale Lift Trucks in Greenville, N .C. "But many times loads or routes have changed since the last time they purchased trucks. You can't assume what was suitable in the past will work for the future."
Just as your applications may have changed, the truck models themselves have likely undergone a few alterations since the last time you were in the market. For instance,says Levine, many of the older trucks advertised as having a 4,000-pound load capacity could actually move more than that—which meant operators weren't afraid to use them to move the occasional 4,500-pound load. Nowadays, however, a truck rated at 4,000 pounds can't go over that limit. Assuming it can and using it for that purpose could cause premature wear or endanger workers.
Staying in shape
As with any vehicle, lift trucks need periodic maintenance to stay in top operating condition. That's a thorough going-over, not just an occasional lube job. " If you don't maintain your lift trucks properly," says Lyle Pichelman, sales engineer at SJF Material Handling in Winsted, Minn., "they'll die on you when you need them the most." A neglected lift truck depreciates rapidly, he warns. "When the time comes to replace it, the value will be a fraction of what it should be."
The obvious way to keep your lift trucks out of the repair bay is to heed the manufacturers' recommended preventative maintenance schedules. "If the repair manual recommends changing the hydraulic fluid every 200 hours, change the fluid every 200 hours," says Boyd.
That also means following the OEM's recommendations to the letter. If, for example, the manufacturer recommends using boron-free engine coolant, don't substitute a cheaper coolant containing boron. That substitution could cause costly and irreversible damage to aluminum intakes and aluminum core radiators. In fact, it may be in your best interest to take the trucks back to the OEM for servicing, says Levine. Today's trucks are more sophisticated than their older counterparts, requiring a great deal of technical know-how on the mechanic's part, he notes."It's not like in the past where a simple fix could do it."
Richard Graumann, manager of aftermarket sales at The Raymond Corp., suggests tracking maintenance and downtime trends to identify vehicles that could be mismatched to their applications or nearing the end of their useful lives.
Daily pre-shift inspections—which are required by OSHA—can alert operators to developing problems, too. Dirk Von Holt, president of Jungheinrith Lift Trucks in Richmond, Va., strongly advocates making it the driver's responsibility to begin his or her shift with a thorough inspection. That includes checking fuel, battery electrolyte, oil and coolant levels as well as the condition of the forks, carriage chains, tires and even the seat belts.
Run it right
Of course no maintenance program can offset the wear and tear caused by screeching stops, stut tering starts and careening turns. Levine says that one of the most common misconceptions about lift-truck operation is that anyone can do it. "There's no reality to the thinking that if you can drive to work, you can drive a forklift truck," he says.
Though OSHA issued specific lift truck training standards in 1999, training efforts still tend to be spotty. Training costs money, to be sure, but managers who take the training requirement seriously will save the company money in the long run. Whether they outsource training or handle it inhouse, operations that follow the protocol laid out in the standard generally have fewer accidents, and therefore, report less down time and enjoy lower insurance rates.
But the benefits don't end with lower insurance rates and less downtime. Training can lead to more productive operations as well. "Operators that have been fully trained on a particular piece of equipment tend to be more comfortable using it because they're familiar with how it will respond in a given situation," says Boyd."Operators who have not gone through the training are often hesitant in certain operating situations because they are not clear on how the lift truck will respond. This hesitancy undoubtedly has an effect on productivity."
Supply chain planning (SCP) leaders working on transformation efforts are focused on two major high-impact technology trends, including composite AI and supply chain data governance, according to a study from Gartner, Inc.
"SCP leaders are in the process of developing transformation roadmaps that will prioritize delivering on advanced decision intelligence and automated decision making," Eva Dawkins, Director Analyst in Gartner’s Supply Chain practice, said in a release. "Composite AI, which is the combined application of different AI techniques to improve learning efficiency, will drive the optimization and automation of many planning activities at scale, while supply chain data governance is the foundational key for digital transformation.”
Their pursuit of those roadmaps is often complicated by frequent disruptions and the rapid pace of technological innovation. But Gartner says those leaders can accelerate the realized value of technology investments by facilitating a shift from IT-led to business-led digital leadership, with SCP leaders taking ownership of multidisciplinary teams to advance business operations, channels and products.
“A sound data governance strategy supports advanced technologies, such as composite AI, while also facilitating collaboration throughout the supply chain technology ecosystem,” said Dawkins. “Without attention to data governance, SCP leaders will likely struggle to achieve their expected ROI on key technology investments.”
The British logistics robot vendor Dexory this week said it has raised $80 million in venture funding to support an expansion of its artificial intelligence (AI) powered features, grow its global team, and accelerate the deployment of its autonomous robots.
A “significant focus” continues to be on expanding across the U.S. market, where Dexory is live with customers in seven states and last month opened a U.S. headquarters in Nashville. The Series B will also enhance development and production facilities at its UK headquarters, the firm said.
The “series B” funding round was led by DTCP, with participation from Latitude Ventures, Wave-X and Bootstrap Europe, along with existing investors Atomico, Lakestar, Capnamic, and several angels from the logistics industry. With the close of the round, Dexory has now raised $120 million over the past three years.
Dexory says its product, DexoryView, provides real-time visibility across warehouses of any size through its autonomous mobile robots and AI. The rolling bots use sensor and image data and continuous data collection to perform rapid warehouse scans and create digital twins of warehouse spaces, allowing for optimized performance and future scenario simulations.
Originally announced in September, the move will allow Deutsche Bahn to “fully focus on restructuring the rail infrastructure in Germany and providing climate-friendly passenger and freight transport operations in Germany and Europe,” Werner Gatzer, Chairman of the DB Supervisory Board, said in a release.
For its purchase price, DSV gains an organization with around 72,700 employees at over 1,850 locations. The new owner says it plans to investment around one billion euros in coming years to promote additional growth in German operations. Together, DSV and Schenker will have a combined workforce of approximately 147,000 employees in more than 90 countries, earning pro forma revenue of approximately $43.3 billion (based on 2023 numbers), DSV said.
After removing that unit, Deutsche Bahn retains its core business called the “Systemverbund Bahn,” which includes passenger transport activities in Germany, rail freight activities, operational service units, and railroad infrastructure companies. The DB Group, headquartered in Berlin, employs around 340,000 people.
“We have set clear goals to structurally modernize Deutsche Bahn in the areas of infrastructure, operations and profitability and focus on the core business. The proceeds from the sale will significantly reduce DB’s debt and thus make an important contribution to the financial stability of the DB Group. At the same time, DB Schenker will gain a strong strategic owner in DSV,” Deutsche Bahn CEO Richard Lutz said in a release.
Transportation industry veteran Anne Reinke will become president & CEO of trade group the Intermodal Association of North America (IANA) at the end of the year, stepping into the position from her previous post leading third party logistics (3PL) trade group the Transportation Intermediaries Association (TIA), both organizations said today.
Meanwhile, TIA today announced that insider Christopher Burroughs would fill Reinke’s shoes as president & CEO. Burroughs has been with TIA for 13 years, most recently as its vice president of Government Affairs for the past six years, during which time he oversaw all legislative and regulatory efforts before Congress and the federal agencies.
Before her four years leading TIA, Reinke spent two years as Deputy Assistant Secretary with the U.S. Department of Transportation and 16 years with CSX Corporation.
Serious inland flooding and widespread power outages are likely to sweep across Florida and other Southeast states in coming days with the arrival of Hurricane Helene, which is now predicted to make landfall Thursday evening along Florida’s northwest coast as a major hurricane, according to the National Oceanic and Atmospheric Administration (NOAA).
While the most catastrophic landfall impact is expected in the sparsely-population Big Bend area of Florida, it’s not only sea-front cities that are at risk. Since Helene is an “unusually large storm,” its flooding, rainfall, and high winds won’t be limited only to the Gulf Coast, but are expected to travel hundreds of miles inland, the weather service said. Heavy rainfall is expected to begin in the region even before the storm comes ashore, and the wet conditions will continue to move northward into the southern Appalachians region through Friday, dumping storm total rainfall amounts of up to 18 inches. Specifically, the major flood risk includes the urban areas around Tallahassee, metro Atlanta, and western North Carolina.
In addition to its human toll, the storm could exert serious business impacts, according to the supply chain mapping and monitoring firm Resilinc. Those will be largely triggered by significant flooding, which could halt oil operations, force mandatory evacuations, restrict ports, and disrupt air traffic.
While the storm’s track is currently forecast to miss the critical ports of Miami and New Orleans, it could still hurt operations throughout the Southeast agricultural belt, which produces products like soybeans, cotton, peanuts, corn, and tobacco, according to Everstream Analytics.
That widespread footprint could also hinder supply chain and logistics flows along stretches of interstate highways I-10 and I-75 and on regional rail lines operated by Norfolk Southern and CSX. And Hurricane Helene could also likely impact business operations by unleashing power outages, deep flooding, and wind damage in northern Florida portions of Georgia, Everstream Analytics said.
Before the storm had even touched Florida soil, recovery efforts were already being launched by humanitarian aid group the American Logistics Aid Network (ALAN). In a statement on Wednesday, the group said it is urging residents in the storm's path across the Southeast to heed evacuation notices and safety advisories, and reminding members of the logistics community that their post-storm help could be needed soon. The group will continue to update its Disaster Micro-Site with Hurricane Helene resources and with requests for donated logistics assistance, most of which will start arriving within 24 to 72 hours after the storm’s initial landfall, ALAN said.