4 Ways to Improve Forklift Efficiency

by Dan Livingston, on April 2, 2021 at 6:48 PM

4 Ways to Improve Forklift EfficiencyEver seen a Lambo or Ferrari stuck in traffic? There's an expensive car built to go 200 miles an hour, going two miles an hour. It's funny or sad depending on how you feel about people who buy expensive sports cars. 

Just like a high-performance car can be paralyzed by congestion, your productivity can be held back by external factors. But unlike traffic on I-5 or I-90, there's actually something you can do about it! Read on for four different ways you can improve the efficiency of your operation by helping forklift operators be more productive.

4 Ways to Improve Forklift Operator Efficiency

1. Optimize Facility Layout

How much time do your operators spend just driving around? If your forklift has a telematic device, the data can tell you. If you don’t use telematics, or if you’d like some expert help digging through the numbers, let us know. Mid-Columbia Forklift and MidCo Material Handling provides free warehouse optimization consultations.

One of the most effective ways to make your facility more efficient is to reorganize it. It’s a short term pain in the butt, but you’ll enjoy significant long-term productivity gains. When forklift operators have to go back and forth across your facility to fill one order, that’s an efficiency killer - death by a thousand cuts.

Layout optimization doesn't have to mean reorganizing your entire workplace. It could be as simple as:

  • Moving popular items near each other and closer to packing/staging areas
  • Identifying and alleviating areas of congestion 
  • Adding traffic control devices or designated forklift travel areas
  • Converting certain areas to a new pallet racking system

2. Training and Cross Training

Your experienced forklift operators are a wealth of information. OSHA forklift training teaches new operators the basics, but insights from experienced team members — who know your facility upside down and backwards — will help new hires navigate your workplace more efficiently.

Assigning new operators an experienced mentor pays generous dividends in efficiency and safety. Sometimes new employees need to hear from their peers:

  • We want you to do a thorough pre-shift inspection
  • It’s okay to ask for a spotter
  • X route is shorter but always congested; go Z way instead
  • Beware of Bill from accounting. He never pays attention when he walks through the warehouse.

Once the new employee gets settled in, cross-train them on other equipment or tasks, like battery watering or cycle counts. Extra responsibility can make employees feel valued, and you never know when you’ll need an extra set of hands to finish a job.

3. Invest in Attachments, Accessories and Ergonomic Equipment

The Best Forklift Attachments to Improve Productivity is one of our most-read articles — and for good reason. You’ll be amazed by the productivity gains your operators will achieve with a:

  • Sideshifter
  • Fork positioner
  • or Multi-load handler (single-double)

If the items above aren't in your budget, ergonomic accessories are always a worthwhile investment. Fatigue and injuries are the kryptonite of efficiency. Here are a few items we recommend:

  • A new operator’s seat (they should be replaced every three years)
  • Forktip lasers
  • A camera system
  • A grab handle with horn for traveling in reverse

4. Ask Your Operators for Ideas

The people closest to a problem typically have the best solutions, and when you ask your team members for input, it makes them feel like MVPs.

At your next operator staff meeting, explain why efficiency is important and ask for suggestions. If the ideas don’t start flowing right away, ask each operator to provide at least one suggestion by the end of the week.

Establish a benchmark and offer a reward for overall improvement and special recognition for best idea(s). When team members are part of the problem-solving process, it gives them ownership of the solution and makes them feel respected and empowered.

Warehouse Equipment and Optimization in Washington State

The experts at Mid-Columbia Forklift and MidCo Material Handling can help you uncover hidden efficiencies and make your operation more profitable. We provide a variety of warehouse optimization solutions, from basic pallet racking to customized automation.

Let us know what problems you want to solve, and we'll help you find the right solution. Getting started is easy with our free, no-pressure consultations.

Contact us online or by phone:

Auburn 253-854-5438
Pasco 509-547-7413
Wenatchee 509-663-9009
Yakima 509-457-5137

Further Reading:
The Best Forklift Attachments to Improve Productivity
How to Choose the Best Pallet Rack for Your Warehouse
When to Repair Vs. Replace Warehouse Pallet Rack

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Topics:Forklift

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Material handling articles to help answer the questions you have about forklifts, aerial equipment, utility vehicles, warehouse optimization, and safety.

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