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Customer Focus

When To Pick a Manual Pallet Jack, Walkie Jack or Walkie Rider Jack

April 26, 2012

Many companies use one of the various forms of pallet jacks (manual, powered walk-behind or powered ride-on) to move product horizontally throughout their facility. Some of the factors that influence their decision include workers comp claims, operator fatigue, productivity and product damage. Knowing the distance traveled by the operator and restrictions of the application will help also you select the right equipment.
Manual Pallet Jack
The manual pallet jack has no power and requires manual pushing and pulling. It is ideal for distances under 40 feet and does not require an operator to attend OSHA compliant training. Unless the movement of product happens at a very low frequency, maybe once an hour, someone shouldn’t expect operators to move loads greater than 2,000 lbs with a manual pallet jack. One back injury can be many times more than the expense of a powered pallet jack.

Walkie Jack
A powered pallet jack that you walk behind (“walkies”) is helpful when operator fatigue is a concern. Although the equipment moves at the same pace of the operator, it does not slow down with longer distances or excessive usage. Walkies are ideal for distances 40-100 feet and are often found in the back of stores, small manufacturing with low volume and delivery trucks. Customers purchasing walkie jacks often need few features but require a powered unit for one of the many reasons described above.

Walkie Rider Jack
If your application requires frequent use or longer travel distances, the walkie rider jack can help reduce operator fatigue and increases safety. With travel speeds of about 8MPH it is more than two times faster than a walking pace. Found often in warehouses and distribution centers with higher volume, this equipment can be used for low lever order picking. With a relatively low acquisition cost, if you are only looking for horizontal movement, it can be an economical replacement for a standard forklift.

 

Click here to learn more about ProLift and its Class III product line or contact us to speak to a consultant. Read more about the benefits of owning Class III equipment.

Forklift UL Ratings

March 23, 2012

OSHA requires all new forklifts, both internal combustion (IC) and electric, be inspected by an independent testing laboratory for their ability to avoid causing a fire in the workplace. Toyota Industrial Equipment and several other forklift manufacturers use Underwriters Laboratories (UL) for all testing. Others use Factory Mutual (FM).

There are 2-4 levels of OSHA ratings for forklifts dependent on the fuel used. The forklift’s rating will be stamped on the data (capacity) tag under the heading of “Truck Type.”

  • Gasoline forklifts are rated G or GS
  • LPG forklifts are rated LP or LPS
  • Diesel forklifts are rated D, DS or DY
  • Electric forklifts are rated E, ES, EE or EX

Each increased level of the rating requires changes to the forklift to reduce the possibility of causing a fire. As an example, diesel “D” rated forklifts are standard. A “DS” rated forklift would have some sealed components and electrical connections such as a starter and alternator to reduce the possibility of an electrical arc. A “DY” rated forklift would have no electrical system. Instead it would have an air operated starter, an air tank to power the starter and many other safeguards. “DY” forklifts have brass coated forks and load back rests. They may also feature a squeeze bicycle horn or bell in place of an electric horn.

When modifying or adding accessories to forklifts, there is a possibility the UL rating could be voided. For example, adding a static chain or strap to the forklift’s frame is crucial to prevent static electricity from interfering with the forklift’s computers. On electric forklifts, adding a steel static chain to an “E” or “ES” forklift is acceptable. However, if the forklift is rated “EE” or “EX”, a steel chain is not approved because it may cause an external spark. On “EE” or “EX” rated forklifts a brass chain or rubber static strap would have to be used.

Click here for more information about OSHA 1910.178 and forklift ratings. If you are concerned about your current lift and its rating, contact a ProLift consultant for help today.

Fleet Management: Do You Know the Real Cost of Your Forklift Fleet?

February 10, 2012

The acquisition cost of a forklift is only one factor in the overall cost of ownership. The majority of costs involve operating and maintenance expenses. While fleet management is widely known in the trucking industry, it is also a big advantage to companies using it for their forklifts and other material handling assets. Oftentimes, implementing a fleet management program results in a significant cost savings and longer equipment life cycle.

Fleet management is not a small project. Without a dedicated resource to manage the project, knowing the real cost of your forklift fleet is nearly impossible. While a vendor specializing in fleet management can be secured, understanding the program and justifying the costs can be daunting.

Below are questions a fleet management program can answer:

Do you operate the right equipment?
Equipment must be suited for the weight and size of the transported product as well as the available warehouse space and racking.

Is every forklift in use?
Based on the hour meter and the number of warehouse shifts, it is important to determine if every forklift is optimized. Every forklift will be located in the warehouse and analyzed for how often it is operated. A forklift used in a lower usage area may be periodically swapped with a forklift used in a high production area.

Do you have too many or too few units?
After determining the usage of each forklift, it will be decided if the size of your fleet is appropriate for your production.

Are forklift operators driving safely?
Unsafe operation results in damage and needed repairs of the equipment. Incidents found to be abuse are not covered under warranty, generating unexpected maintenance costs. Regular forklift training classes and consistent safety messages can be implemented to decrease the amount of incidents.

Are repair and maintenance invoices consistent and accurate?
Determining the budget for repair and maintenance can be difficult. Many administrative hours can be spent processing purchases orders and invoices for the equipment. A thorough review of each invoice for consistency and accuracy will answer if your company spends additional dollars for a lift having the same repair as another lift at a different cost. Analysis of the planned maintenance (PM) frequency can also point to inefficiencies and additional cost. Planned maintenance done too frequently or not often enough can both have negative cost implications.

Do you know why downtime occurs?
Research of downtime may show how the issue originated. Reviewing trends by department, operator and type of equipment can point to areas of opportunity.

When is it time to replace equipment?
Understanding the true cost of ownership is the key to determining whether it is in the best financial interests of the organization to keep or replace existing equipment. A fleet management program will help track the cost per hour of existing equipment while simultaneously running a comparison of the costs associated with acquiring a new unit with comparable specifications. The guess work is eliminated and replaced with concrete data to aid in the decision making process.

Learn more details about ProLift’s fleet management program. Contact us today to speak to a consultant.

Electric Forklifts versus IC Forklifts

January 20, 2012

The great debate … electric forklifts versus IC (internal combustion) forklifts. This decision is not only for new companies. Established companies may also weigh the advantages and disadvantages of each fuel, especially if there is a shift of priorities to “go green.”

Electric Forklifts
The forklift industry has experienced a shift in sales, with electric forklifts now counting for 60% of the market’s purchases.

Electric forklift advantages might include:

  •  Better for the environment – Electric forklifts have zero emissions, which eliminate an employee’s exposure to contaminated air and the need for warehouse ventilation. They use no disposal waste (i.e. engine and transmission fluid) and a high percentage of battery lead is recycled.
  • Operator ergonomics – Less noise and vibration is generated by the electric forklift, reducing operator fatigue.
  • Decreased repair costs – Electric forklifts have less moving parts to maintain and repair. AC motor technology further eliminates brushes to create no spark hazard and better speed control.
  • Lower fuel costs – Batteries for the electric forklift can be recharged.

With these advantages come other factors to consider. Although electric forklifts have lower lifetime fuel costs, the initial cost is higher. In addition to the cost of the battery, an area for charging, watering and cleaning must be arranged. Electric forklifts are at a disadvantage when using the forklift in an outdoor application, especially if the environment is wet. Downtime can also be experienced if the battery is not charged or equalized properly.

IC Forklifts
The market is still strong for IC forklifts. They account for about 40% of the market and are dominant in outdoor, around-the-clock or high throughput applications.

IC forklift advantages might include:

  • Flexible application – IC forklifts are good indoors and outdoors. They operate well in rain and other inclement weather.
  • When throughput requirements are high – The fuel savings associated with electric trucks is greatly diminished or negated when multiple batteries are required to keep an operation running. Furthermore, electric trucks have slower travel speeds and acceleration which may necessitate additional equipment and personnel to move the same amount of product.
  • Lower initial cost – Only the investment of propane tanks and their storage area is needed to operate the forklift.
  • Easy to refuel – IC forklifts running out of fuel do not require a lengthy charging period. An operator can easily replace the propane tank in 5 minutes and then continue production. This is especially important with a multi-shift operation.

Other factors to consider when purchasing an IC forklift include providing ventilation in the warehouse due to emissions, operator fatigue due to noise and vibration and the physical requirements of changing propane tanks. Finally, if the operation does not require an IC forklift you should consider the lifetime costs of maintenance, repairs and fuel cost when compared to an electric forklift.

To compare electric forklifts versus IC forklifts for your company, email ProLift at info@proliftequipment.com to request a Costs Summary spreadsheet.

Forklift Safety: Can You Remove the Forklift’s Load Backrest?

January 12, 2012

The load backrest can be the highest point of the forklift. Trailer tops, rack systems, lights, HVAC, sprinkler systems and other overhead obstructions come in contact with load backrests.

If an object above the forklift gets hit, do you blame the load backrest … or the operator?
To put another spin on this question, if a co-worker said “I keep backing into things with the bumper on my pick-up truck”, would you suggest removing the bumper? Or would you mention to your co-worker that he or she needs to be more alert to hazards near the pick-up truck?

Many times the answer to a customer’s question about removing the load backrest is “Yes, remove it and remind your forklift operators to be careful.” But, this is not an accurate answer representing OSHA’s code of federal regulations? (*See below)

The answer is a conditional “yes”. All loads handled by the forklift and the facility it operates within must meet one of the requirements below:

1)      All loads do not go higher than the top of the forks.

2)      All loads are one piece, shrink wrapped, banded or crated.

3)      No loads in the facility are stacked or racked higher than the operator’s head that does not meet the load requirements above. Lift trucks with the load backrest removed must be restricted to handling only loads meeting the requirements above or is restricted to a specific area of the facility that does not contain any loads presenting a hazard.

Provide safe operations while meeting OSHA requirements
Forklift manufacturers offer various heights for the load backrest. When selecting a lift truck, research the warehouse application and the heights of loads to purchase load backrests that meet rather than exceed the requirements. The proper load backrest will provide protection for the forklift operator while reducing the possibility of product and facility damage.

Other solutions include shrink wrapping or banding the loads and restricting a forklift with a removed load backrest to specific areas (i.e. the dock for loading and unloading trailers).

Do you have employees in need of lift truck safety training or pedestrian awareness? Contact ProLift to discuss available training and dates.


* Federal Regulations
OSHA CFR1910.178(e)(2)
Safety Guards: If the type of load presents a hazard, the user shall equip fork trucks with a vertical load backrest extension.

OSHA CFR1910.178(m)(10)
Truck Operations: A load backrest extension shall be used whenever necessary to minimize the possibility of the load or part of it from falling rearward.

OSHA CFR1910.178(q)(6)
Maintenance of Industrial Trucks: Industrial trucks shall not be altered … either by the addition of extra parts … or by the elimination of any parts.

 

 

Forklift Safety: Trash on the Floor – Big Deal!

Lift trucks are used in various environments. They are exposed to shrink wrap, banding materials and other debris from the manufacturing and warehouse process.

Is housekeeping important to the safe and proper operation of a powered industrial truck? … Yes!

OSHA CFR1910.143(a)(3) Housekeeping.
All places of employment shall be kept clean to the extent that the nature of the work allows.

If plastic banding material can hold a 3,000 lb load together, imagine what it can do to brake lines, park brake systems, steering systems and axle seals and bearings when tightly wrapped around the wheels and axles of an operating lift truck!

Ground clearance of lift trucks is generally kept to a minimum for stability concerns. This makes it easy for materials on the floor to get caught in rotating assemblies. The cooling systems are designed to pull air off the floor underneath the truck, push the air through the radiator and out the back of the truck. This creates a “vacuum effect” that sucks debris (i.e. shrink wrap and dust) into the mechanisms and radiator of the lift truck. This can cause damage and overheating.

OSHA CR1910.178(q)(9) basically states it is illegal to operate an overheating lift truck. Why? When overheating, the lift truck does not meet UL classification. It can become a source of ignition for other materials or a fire hazard itself.

Serious or fatal accidents can also be the result of a lift truck damaged by floor debris. It takes only one piece of banding to compromise the brake or steering systems. Operators can lose control of heavy equipment, possibly costing someone their life.

It is important to promote housekeeping within your warehouse. The removal of floor debris hazards matters to everyone’s safety.

 

Do you have operators in need of lift truck safety training? Contact ProLift to discuss available training and dates.

Is It Time To Upgrade Your Forklift?

As service invoices stack up for your used forklift, it may be time to consider the replacement of the forklift. To determine if the service costs are reasonable and easily explained, follow these best practices.


Cost per hour
Many companies struggle to justify the purchase of a new forklift because the current one is paid in full. However, when a repair is needed, it can often drive the cost per hour well above industry averages. Your best indicator of forklift replacement is the utilization and cost per hour according to the unit’s maintenance history. It’s best to have at least 12 months of maintenance history; however, using several years of data is beneficial to ensure accuracy (i.e. production may peak during a specific season or your company had a short-term project affecting forklift usage).

Number of hours
Typically, an internal combustion (IC) forklift with over 10,000 hours or an electric forklift with over 12,000 hours is due for replacement. Forklifts with high hours will experience failures with major components such as mast chains, carriage and mast rollers, shimming and transmission or drive train work. Electric forklifts will also need battery replacement.

Hidden costs
There are hidden costs of keeping dated equipment as related to safety, ergonomics, emissions and efficiency. An aging truck lags in efficiency, making it harder for you to keep the same production pace. Newer equipment will have technology improvements. For example, forklifts built prior to 2006 protect your warehouse from harmful emissions.

If your company experiences a significant change in product or application, using the wrong forklift can result in additional costs. Examples of poorly applied equipment would be: operating electric forklifts outside, utilizing reach trucks for unloading trailers, using non-freezer package forklifts in a freezer or lifting loads heavier than the capacity of the forklift.

Getting Started
To stay aware of your forklift’s maintenance history, create a separate expense category for forklift maintenance. The most effective forklift maintenance tracking systems also include categories for expenses. Examples might include: tires, planned maintenance, damage and breakdown. This can be accomplished in-house or by contracting with a company for Fleet Management services. Create a check and balance system for hitting expenses against the right asset. On the completed invoice, capture whether the repair was due to abuse. Hour meter readings are also critical input.

 

If you would like more information on ProLift and its Fleet Management services, contact us today to speak to your consultant.

Forklift Maintenance Programs: Guaranteed Maintenance vs Planned Maintenance

December 22, 2011

After investing in a new or pre-owned forklift, consideration should be made to enhancing the asset’s life through regular maintenance. The two most common options are guaranteed maintenance and planned maintenance.

With both programs, experienced technicians will catch potential problems early. Customers will avoid safety issues, costly breakdowns and hours of lost productivity. The servicing dealer will also provide the customer with critical documentation including tracking dates of the forklift’s maintenance schedule as well as detailed records of inspections and repairs.

Below is a comparison of the programs:

Guaranteed Maintenance Program (GM)

Guaranteed Maintenance (also known as Full Maintenance) programs are designed to free the customer from the challenges associated with the ongoing upkeep of the equipment.  A typical GM program includes all of the manufacturer’s recommended periodic services and repairs for breakdowns of major components.

The main advantage to a GM program is the predictable monthly costs. The customer pays a fixed rate and in some cases is offered a complimentary forklift loaner when a service repair experiences an extended downtime.  This allows the customer to easily budget for the costs associated with owning a fleet of forklifts. 

The forklift service provider is responsible for maintaining the unit’s records (i.e. dates of service, hours of usage, repairs) and is motivated to reduce costs for the customer by identifying abuse damage or needed rotation of the equipment fleet.

Before a company arranges a GM program, it should consider the service history of the forklift fleet. If the forklift fleets utilization is low and the costs have been reasonable, predictable and almost always in budget, a GM rate may be too high. GM rates are based on an expected cost per hour over a given time frame. The higher the utilization, the higher the expected costs.

Planned Maintenance Program (PM)

Planned Maintenance Programs are designed to ensure that the basic services (engine oil changing, filter replacement, detailed mechanical inspection, etc.) are completed on a regular basis.   However, they do not include major periodic services such as transmission flushes or breakdowns. 

A PM program offers flexibility to customers, having no long-term agreements. Billing is only for parts and labor utilized and the service work is recorded by the job. Companies with a lower amount of working hours on their forklift can set the schedule less frequently to keep costs in line.

Unlike a GM program, the customer is involved in managing the repairs and costs of the forklift. The costs are not locked in and can be unpredictable.

Interested in comparing our maintenance program with your current service? If you are using a competitor program or servicing your equipment in-house, contact ProLift to request your certificate for a complimentary PM service or information on a GM program.

Forklift Rental Purchase Option – Is It To Your Advantage?

November 21, 2011

If you have a long-term need, but are not ready to commit to purchasing forklift equipment, a Rental Purchase Option (RPO) is a solution for your company. A Rental Purchase Option allows your company to put portions of your monthly rental payment toward the purchase of the equipment, but doesn’t commit you to the acquisition.

When a RPO Is Your Better Option

Try it before you buy it
When you have uncertainty about the forklift handling your application, a RPO gives your operators an opportunity to use the unit while handling your product. This is especially advantageous when the materials and loads vary.

If your company has plans to update the forklift fleet and is considering a new equipment manufacturer, a RPO gives the operators hands-on experience with the lift. In addition to gaining a comfort level with the forklift, operators can provide feedback on the operation of the unit.

Money isn’t currently budgeted
Because forklift equipment is a large investment, oftentimes companies budget for the expense. If you need equipment before budget funds are secured, a RPO helps to get the unit to your facility prior to the sometimes lengthy approval process. Rental rates can be paid on a monthly basis and the term can be as short as 30 days.

Having the forklift as a RPO also helps the budget in regards to maintenance. While your company is paying the monthly rental rate, basic maintenance and breakdown repairs are handled by the vendor.

Spike in business
If your company experiences increased business, you may doubt the production level will continue long-term. However, if the short-term forklift need turns permanent, a RPO can significantly reduce the acquisition cost by applying a portion of the rent toward the forklift that has proven itself in your application.

Want to learn more about placing a forklift on a Rental Purchase Option (RPO)? Contact ProLift  for more information.

Forklift Tire Replacement: Bad Forklift Tires Equal a Bad Ride

November 10, 2011

When addressing concerns about your company’s forklift tires, you can feel as much despair as the little boy in the picture. More than frustration, bad forklift tires can be a serious safety issue that can create stability issues for the truck and its load.

Forklifts do not utilize suspension systems with springs or air-ride similar to over the road trucks. They use a suspension system much like a farm tractor. The front axle is solid mounted in the frame of the truck. The rear axle is mounted on a pin in the center of the axle. This design allows the solid front axle to stay in contact with uneven surfaces as the rear axle pivots in the center. The only cushion or yield your operator has between the ground and his or her lift is the rubber or air of the forklift tire.

Bad forklift tires equal a bad ride. A bad ride results in upset operators and loads, increased maintenance costs, damaged facilities and possible forklift stability issues.

Operators who endure the operation of a forklift with chunked, worn or flat spotted tires have increased fatigue and job stress, possibly making them angry, disagreeable and unproductive employees. If an operator is not focused on his or her operation, there can be serious ramifications to everyone’s safety.

Forklifts subjected to deficient tires increase exponentially in maintenance costs. A lack of tread initiates spinning of the tire and more turns to cover the given distance, causing increased heat, wear on the transmission and increased fuel costs. Decreased ground clearances subject the truck to more damage to assemblies underneath. Having little to no cushion from worn forklift tires loosens hardware on the unit which can cause engines and transmissions to leak. Fork heel wear is accelerated as it becomes easier for an operator to drag the forks. Battery cycle time can be affected on electric lifts.

Loads can be compromised by the constant jarring and rocking, leading to damaged product and safety issues such as an upset forklift load falling on an employee.

Your facility can experience damage due to bad forklift tires. A lack of tread can cause operators to lose control of the forklift, hitting production machines, door frames, racks and walls. Accidents can damage dock and bridge plates, blacktop or concrete.

Stability of a forklift can be affected by the condition of the tires and air pressure. When solid rubber tires wear excessively on one axle, it changes the tilt angle of the mast. The severe change in maximum tilt angle can create tip-over or loss of the load. Air filled forklift tires with damaged sidewalls or tread are also at risk for tip-over and damaged product if a tire suddenly blows or low air pressure creates an unstable forklift that leans when loaded.

To ensure your company’s forklift tires are not worn, regularly inspect them for loss of tread, signs of separation from its band or damage. Cushion forklift tires should be measured to determine the height of the tire. An industry standard is replacing the forklift tire when it reaches just above the imprinted area with the brand name and size of the tire. For pneumatic forklifts, inspect the tires for cracks, splits or little tread.

 

Interested in a complimentary forklift tire inspection? Contact ProLift to request an on-site tire application survey. Or, click here to learn about our comprehensive industrial tire inventory.

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