In the material handling industry, conventional wisdom often dictates operational decisions. However, these ‘accepted truths’ should be regularly re-evaluated, especially when substantial costs are involved, such as maintaining a forklift fleet. Evolving industry dynamics and expanding options necessitate a fresh perspective. For example, is sticking with a single manufacturer truly the most cost-effective strategy?
**Challenging the Single Manufacturer Approach**
Many companies favor a single manufacturer for their forklift fleet (e.g., Toyota or Hyster for internal combustion trucks, Crown or Raymond for electric). While convenient for purchase and lease agreements, the primary driver is usually simplified maintenance. Full-service leases promise predictable maintenance costs, but often exclude component failures beyond the factory warranty or wear items like brakes, leaving room for unforeseen expenses. Sticking to one supplier seemingly streamlines parts stocking and technician training. However, this convenience may come at a price.
No single forklift manufacturer excels in every operational aspect. Electric forklifts offer quiet, emission-free operation but have limited range. Narrow-aisle warehouses might require specialized solutions like turret trucks. The ideal approach involves identifying the best-suited forklift for each specific task, regardless of manufacturer. This might result in a multi-brand fleet across different locations, which, contrary to common belief, doesn’t automatically translate to a maintenance nightmare.
By strategically selecting forklifts optimized for specific tasks, maintenance demands for each brand are likely to decrease due to enhanced performance and reduced component stress. While a larger initial parts inventory might be necessary, specialized technician training can offset costs. For instance, instead of training all technicians on a single brand, each can specialize in a particular brand within the fleet.
**Refurbished vs. New: A Reassessment**
Another outdated notion is that refurbished forklifts, despite being cheaper, are inherently unreliable. However, the rising cost of new equipment has fueled a thriving market for reconditioned lift trucks. A proper refurbishment involves disassembling the unit to its bare frame, sandblasting, repainting, and rebuilding it with meticulous quality control to ensure reliable performance under heavy use.
It’s vital to clarify what ‘refurbished’ entails. Ensure the unit has undergone complete disassembly, inspection, and reassembly, with engine overhauls to restore it to like-new condition. While purchasing used forklifts carries risk, acquiring quality refurbished ones doesn’t have to. The market now offers factory-reconditioned forklifts at roughly one-third the cost of new ones, available in fleet-suitable quantities.
These renewed forklifts have undergone a ‘shakedown cruise,’ with weaker components replaced. This can result in a more reliable unit. While a refurbished truck has a shorter service life than a new one, consider this scenario: purchasing a refurbished unit at one-third the cost of a new one allows you to bypass the initial high maintenance phase. Regular maintenance and slightly earlier retirement can avoid the final stage of high maintenance, resulting in substantial savings and potentially lower overall maintenance costs.
**Brand Name vs. Off-Brand Parts**
Finally, consider the common belief that sticking to brand-name parts is always the safest option. While seemingly logical, this isn’t always the case. The rise of global manufacturing has introduced cost-effective alternatives without sacrificing quality.
Many factories, particularly in China, have long produced parts for major forklift brands. Now, they are selling directly in the United States at significantly lower prices. These parts are often made by the same manufacturers as the brand-name components but are less expensive due to streamlined distribution, eliminating dealer markups and manufacturer profit centers on spare parts. These savings mitigate the perceived higher maintenance costs associated with multi-manufacturer or refurbished fleets.
Ultimately, fleet decisions should be based on a clear understanding of operational requirements and which forklifts, new or refurbished, can most effectively and economically fulfill those needs.