Material handling equipment is crucial for the global supply chain to run seamlessly. Equipment downtime can cost even the biggest revenue-generating company billions of dollars every year. It is the top priority of many companies to eliminate downtime. We have put together some tips to keep downtime at bay. But before that: 

What is downtime?

Downtime, in this context, refers to any unforeseen event which can hinder the production for any amount of time. Major causes of unplanned downtime could be operator error, poor maintenance, hardware or software error, and poor performance. 

Planned downtime, on the other hand, is done deliberately in case of software or hardware upgrades or planned maintenance. Planned downtime is not usually calculated in downtime costs.

Tips to avoid unplanned downtime:

• Pre-shift inspections

It is essential to conduct pre-shift inspections of the forklifts, pallet jackets, and tow trucks to ensure the maximum safety of workers. Pre-shift inspections also help to identify any small problem in its initial stage. This could save companies from a big repair bill later if the problem persists and escalates. Some problems like small oil leaks, noisy drive motors, and intermittent electrical shorts are small enough to not get noticed but can transform into a big issue over time.

• Regular maintenance schedule

Most companies don’t know when their machinery is due for repairs. Statistics even claim this number to be over 70%. It may lead to very expensive downtime and potential risk hazards too.  

A simple hack to get on top of maintenance is to keep track of how many hours your equipment is used. You can even maintain a spreadsheet or a computerised maintenance management system (CMMS). You should always follow the manufacturer’s recommendations as different pieces of equipment may require different maintenance routines. Checking the operator’s manual could be helpful.

• Better trained staff

The staff who handles the equipment daily should also be trained properly. Poorly trained staff can mishandle and severely damage the equipment. It’s essential to train them to avoid any incidents at the workplace as well as unplanned downtime. A quality operator training program ideally consists of- formal instruction and hands-on training. The final certification should be provided by the employer. It should be based on the operator’s performance in the actual areas and conditions of the facility where they’ll be operating.

• A floor cleaning plan

Warehouses often have debris from broken pallets, boxes, and dust posing a threat to forklift tires. And the damage would ultimately lead to downtime, increased fuel costs, and potential injury to the operator. Regular floor scrubbing can ensure the safety of forklift tires and pedestrians alike. 

• Taking care of Batteries

The lead-acid industrial batteries which power the electric forklifts and other powered industrial trucks are more susceptible to depreciation. With an increased demand in production, the pressure to keep the lifts running has also increased. This is why it’s important to fully charge the batteries before putting them back into service. 

Filling the cells with an adequate amount of water would maximise the life of batteries.

• Select the right equipment

Equipment downtime is the biggest threat to profitability any company could face. Choosing the right equipment for your needs could go above and beyond. Before you invest in a piece of equipment, ask yourself- is the configuration of this forklift something I can rely on? Is there any other model with added features that could benefit me in the long run? Do I need other specialised equipment to meet any functional needs? 

By focusing on these points you can further optimise your equipment and reduce the likelihood of unplanned downtime. 

• Keep a track of machine’s economic life

When a piece of equipment comes close to the end of its useful life, it becomes more expensive to continue maintaining it. By keeping a track of your equipment’s economic life you can avoid downtime by timely replacing it with something newer.

To conclude, downtime certainly causes a lot of damage to both- productivity and financial losses. Companies should do whatever they can to reduce the amount of time the material handling commission is down and not running. These simple steps could go a long way in running your equipment smoothly.