Our Blogs Reducing Downtime with Proper Handling Equipment Maintenance

Date Posted:20 November 2024

By implementing a regular maintenance schedule, training employees, and using predictive technology, businesses can significantly reduce the chances of unexpected equipment failure

Downtime is a costly issue for many businesses, particularly those relying on material handling equipment to keep operations running smoothly. However, with proper maintenance of your handling equipment, you can significantly reduce unexpected breakdowns and improve overall productivity.

1. Create a Regular Maintenance Schedule

The first step to avoiding downtime is setting up a consistent maintenance routine. Every type of equipment—from forklifts to trolleys—needs regular checks and servicing. By having a documented maintenance schedule, you can prevent equipment from suddenly malfunctioning due to wear and tear. Include daily, weekly, and monthly checklists that cover the essential components of your material handling tools.

Maintenance tasks can include:

Lubricating moving parts
Inspecting hydraulic systems for leaks
Checking for wheel damage on trolleys and carts
Tightening loose bolts or screws

2. Train Employees on Proper Equipment Use

Misuse of equipment is another leading cause of unplanned downtime. Ensure all operators are trained not only in how to use the machinery but also in understanding its maintenance needs. Operators who are familiar with how equipment works will be able to identify early warning signs of malfunction.

Implement a formal training program that includes:

Proper use of equipment
Daily inspections by operators
How to report malfunctions immediately

3. Perform Pre-Operation Inspections

One of the easiest ways to reduce downtime is to inspect equipment before use. A pre-operation inspection ensures that any problems are caught early before the equipment fails during critical operations. Employees should check brakes, wheels, steering, and any power-driven components before starting their shift.

4. Use Quality Replacement Parts

When equipment does break down, using substandard replacement parts can lead to more frequent repairs and longer downtimes. Always source high-quality parts from reputable suppliers to ensure the longevity and reliability of your equipment.
Additionally, keeping a stock of essential spare parts, such as belts, bearings, and tyres, can help you quickly address repairs without waiting for parts to arrive.

5. Implement Predictive Maintenance

Predictive maintenance uses technology to monitor the condition of equipment in real-time. Sensors can detect vibrations, temperature changes, or irregular operations, helping to predict when a failure might occur. This allows businesses to perform maintenance before a critical failure happens.
For example, a forklift's hydraulic system can be fitted with sensors to monitor pressure levels. If the system detects an anomaly, the equipment can be taken out of service for repairs before it breaks down.

6. Address Wear and Tear Immediately

Over time, all equipment experiences wear and tear. However, ignoring minor issues can lead to more severe breakdowns. For example, a trolley with a wobbly wheel might seem like a small problem, but if left unaddressed, it could cause the entire trolley to malfunction during operation.
Employees and supervisors should be vigilant and proactive in repairing small issues as soon as they arise. This will help extend the lifespan of your material handling equipment and reduce unexpected downtime.

7. Keep Equipment Clean and Well-Lubricated

Dust, dirt, and debris can easily accumulate in machinery, leading to blockages, overheating, or unnecessary wear. Regular cleaning and lubrication are essential maintenance practices that keep equipment running smoothly.
Proper cleaning should involve:

Removing dust and debris from moving parts
Cleaning out any filters
Lubricating gears, chains, and wheels regularly

Using the right lubricants and cleaning agents designed for your specific equipment is also vital for maintaining optimal performance.

8. Use Data to Improve Maintenance Procedures

Modern maintenance systems allow you to track and analyse equipment performance data. By reviewing past breakdowns, repair logs, and maintenance schedules, you can identify trends and areas where improvements can be made. This data-driven approach ensures your maintenance team is proactive rather than reactive, minimising downtime caused by repeated failures.

9. Outsource Complex Repairs

While minor repairs and maintenance can be handled in-house, outsourcing more complex repairs to professionals ensures that the job is done right. Professionals have the tools, experience, and expertise to fix advanced mechanical or electrical issues, which can save you time and prevent further damage.

10. Consider Upgrading Outdated Equipment

No matter how well you maintain your equipment, outdated machinery will eventually need to be replaced. Newer models often come with enhanced safety features, better energy efficiency, and lower maintenance costs. If your equipment is frequently breaking down despite regular maintenance, it may be time to consider investing in newer technology.

Reducing downtime through proper maintenance of material handling equipment is crucial for maintaining productivity and profitability in any business. By implementing a regular maintenance schedule, training employees, and using predictive technology, businesses can significantly reduce the chances of unexpected equipment failure. Keeping equipment clean, addressing wear and tear early, and outsourcing complex repairs will also contribute to smoother operations.

With a proactive approach to maintenance, businesses can not only minimise downtime but also extend the lifespan of their material handling equipment, ensuring a safer and more efficient workplace.