Fleet Management & Forklift Safety Blog

Cut Costs & Warehouse Inefficiencies by Avoiding These 5 Issues

Posted by Dick Sorenson on May 31, 2018 4:00:00 AM

As a warehouse manager, your job description could probably include: controls chaos, ensures inventory is safely and quickly where it needs to be, and keeps warehouse costs down. But, there are several things happening in your facility right now that may be wasting money and time. directory-1274229_1920

Each day you should be looking for ways to cut out waste and use data insights to improve efficiency. If this is not part of your routine, you could miss these 5 common issues.

5 common warehouse issues to avoid

1. Forklift accidents and mishaps are too common.

Does it seem like a particular safety incident happens way too often lately? There might be a reason. From poor routing to poor operator behavior, it pays to get ahead of the next incident by determining what is causing them and what preventative action is needed.

2. The fleet is moving, but productivity isn’t.

Is your fleet working at capacity? Is there a lot of idle time? Are workers taking extended breaks or not completing tasks efficiently? Is routing causing delays? The “activity” in the warehouse is probably in need of attention.

Use your telematic-monitoring insight to identify the truck(s) and operator(s) bringing down overall results. The right software can tell you exactly where the problem is and how you can address it.

Also note that driver and fuel cost efficiencies result from instantly knowing the shortest path or paths of less congestion. Use real-time monitoring to ensure fleet routing allows for optimum movement.

3. Valuable time is lost running reports.

Reports shouldn’t take you hours to run and analyze. Hanging on to “business as usual” tactics — even if you do it very well — will cost you. Many managers struggle to retrieve and digest data in time to prevent small issues from becoming big problems.

Your platform should do the analyzing for you, providing one-screen access to insight that determines what is going wrong, why, and how to fix it.

4. Forklift batteries are costing you too much.

Improper battery care and charging practices can end battery life prematurely. Look to see if opportunity charging is occurring in your facility because charging a battery too soon reduces its lifespan.

  • Batteries should be monitored and get fully recharged daily when they need it — not based on convenience.
  • Use telematic tools to evaluate which batteries should be replaced and when. Establish replacement cycles based on facts rather than gut instinct.

5. Unauthorized forklift operation is occurring.

Are your drivers using trucks they are not trained to operate? This can result in costly accidents and slowed productivity.  Your telematics system should equip lift-trucks with an identification-card reader, which limits vehicle access to appropriately trained operators. The system also limits driver access to only the specific equipment they are certified to operate.

  • Operator certifications can be required before an operator can use a particular vehicle model.
  • The vehicle can be locked out if the operator is not in compliance.

Cut warehouse costs now

Telematics facilitates exception-based management, allowing you to clearly identify problems and what to do to address them. Take the time each day to focus on solving problems, avoiding costly issues and boosting efficiency.


Topics: goals, value driven strategies, waste stream reduction, lean, cost reduction, OEM Systems