Harnessing Data for Efficient Forklift Fleet Maintenance
Supply chains and warehouses are overflowing with data, although not all of it pertains to product movement. Warehouse and forklift connectivity generates data on worker performance, forklift utilization and equipment health and status. Companies are investing in analytics to leverage this data, aiming to increase productivity, lower costs and enhance safety.
In forklift fleet service and maintenance, greater connectivity delivers value. With the increase of connected service technologies, technicians are now more equipped than ever to make proactive service calls. When data on forklift performance and operation is readily available, supply chain managers can expect service techs to arrive prepared with an understanding of the maintenance issue at hand and the correct parts for repairs.
Connected tools, such as mobile tablets or augmented reality, can assist technicians by guiding them through the repair process. Data gathered from the service call is then uploaded to the service cloud, providing visibility into the maintenance issue and repair, thereby strengthening the service data pool.
As service technicians work with customers to implement a connected maintenance program, warehouse and supply chain executives can utilize forklift data to realize significant fleet maintenance benefits.
1. Reduced downtime
When forklifts are not running, products are not moving. Connected maintenance enables managers and executives to reduce unplanned downtime and the mean time to repair (MTTR). By monitoring forklift performance and health data, managers and service techs can identify symptoms before they become larger issues that result in downtime. This allows service techs to arrive on-site fully prepared to address an issue and shorten MTTR.
2. Predictive maintenance
Connected maintenance allows organizations to transition to a more proactive service and maintenance program. Service providers utilize historical data to diagnose potential causes of issues before techs arrive onsite or even schedule maintenance to anticipate and eliminate potential problems. As forklifts become more connected, service and maintenance programs can utilize software updates and downloads to address certain issues without a service call.
3. Hourly based planned maintenance
Planned maintenance schedules often revolve around fixed equipment maintenance cycles and shutdown periods. Armed with greater connectivity and actionable data on forklift performance, managers can instead align planned maintenance schedules to the business cycle. For instance, if data indicate that certain forklifts have increased operation during a specific period of time, managers can tailor the maintenance schedule to specifically target those trucks and shorten the shutdown period.
4. Visibility into service status
Tracking the progress of a work order once it has been issued is often challenging. Connected maintenance provides managers visibility during every step of the process. Service providers can record information about the issue, service visits and resolutions through established channels and processes. Managers can then create an informed, planned replacement product life cycle formula unique to the organization.
5. Maintenance-by-the-Hour
Unlike a flat-rate monthly maintenance program, businesses can adopt a “Maintenance-by-the-Hour” approach. This strategy aligns maintenance needs directly with forklift usage, adjusting schedules to align with the business cycle. Maintenance costs directly correlate with equipment utilization, and maintenance schedules adapt to peaks and valleys in the business cycle.
As connectivity and forklift data continue transforming the material handling industry, forklift manufacturers are working with customers to establish connected maintenance programs that yield significant benefits and ensure that forklift fleets remain operational and readily available.