Most manufacturers know the cost of raw materials. They know the cost of labour. They know the cost of energy. Yet one of the most difficult costs to quantify is the cost of unplanned downtime. It’s not planned maintenance or a scheduled shutdown, it is an unexpected disruption that happens when production stops or at best has to slow down.
Forklifts are at the heart of all manufacturing businesses, they sit at the heart of operations. They lift, move, carry all day – raw materials, waste and finished products – to keep your production line moving. When a forklift is unavailable, the impact often extends far beyond the truck. Materials run out, waste isn’t moved, finished goods block the production line and then the real trouble starts. Production slots are missed, despatch slows and customers are let down. The whole business is under pressure. It may only take an hour to fix, but the disruption lasts longer.
Choosing the right forklifts and support package is about risk management, not how quickly a breakdown can be fixed. Downtime costs, but lost production costs more.
Why does forklift downtime happen?
Most forklift downtime can be traced back to a small number of common causes.
Ageing equipment...
is the most common as many manufacturers continue operating forklifts well beyond their original replacement cycle, that’s understandable budgets are under pressure and replacing equipment can a significant investment especially if forklift are over specified or for any manufacturers, overpriced.
General wear and tear...
When forklifts aren’t looked after, like most things, they break. For some, preventative maintenance is seen as a cost, not an insurance policy. So for unscheduled problems, engineer call outs and parts are a challenge and more expensive.
Forklifts haven't changed with the operation...
Manufacturing businesses are in a constant state of change, products change, production methods change, volumes change and customer expectations change. So a forklift that was the right choice five years ago may no longer be the right choice today.
Delayed maintenance...
It’s easy to put off, it impacts production and can be seen as a manageable risk unfortunately, small faults rarely remain small and can quickly develop into larger faults that require more extensive repairs and create more disruption.
Slow service response...
When production is impacted, things need to happen fast and that incudes service support. Quick to site, quick to diagnose and quick to fix is the ideal, but a slow response to any of those amplifies disruption. So service support becomes paramount.
Are manufacturers paying more for forklifts than they need to?
In some cases, yes. Manufacturers want reliable equipment that supports growth and changing operational requirements, so it feels like an easy choice to select one of the so-called premium manufacturers. Premium brand, premium price but not usually premium value. More does not mean better, it means more. Forklifts need to be specified to do the job; moving pallets, (un)load vehicles, keep the production line moving. Reliability is key, not the brand so when a forklift can do the job, reliably, that’s what makes it the right choice.
The hidden costs of older equipment
Many balance the cost of keeping older equipment going against the cost of replacements, but operational budgets can often hide the true cost of an individual forklift. Aggregated costs for maintenance, emergency repairs, parts and hiring replacements mask the real cost, so overall it may be manageable, where individually costs can be significant. There is a cost tipping point, but the challenge is spotting it.
Why manufacturers choose HELI
HELI is one of the world’s largest forklift manufacturers, supplying equipment across manufacturing, logistics, distribution and industrial sectors worldwide. HELI’s approach focuses on delivering reliable, practical equipment without unnecessary complexity or unnecessary cost.
A powerful combination with Grant Handling
Choosing HELI is a smart business decision. Grant Handling has over 45 years of forklift experience and is trusted by thousands of operators in the UK. Together, HELI’s quality and advanced technology, combined with Grant Handling’s support, creates a powerful partnership, that delivers unparalleled service, support and value.
Service support is never an afterthought
At Grant Handling we understand that all equipment depends on the quality of the support behind it, so it continues to operate at its best. Our service commitment is focused on maximising your uptime and minimising your costs.
Our team of expert mobile engineers are there when you need them. We understand that when a forklift requires attention, response time matters and effective support is not just about fixing problems it’s about preventing them. Our tailored service packages are designed around your specific requirements, so we can focus on your fleet while you focus on running your business.
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Take the HELI Challenge
See how a HELI forklift performs in your own operation through a practical on-site evaluation.
It is your opportunity to evaluate real world performance in your business. It is completely free. Our Lithium-Ion electric forklifts can take on any challenge.
Perfect for indoor and outdoor applications – from warehouses to manufacturing plants, HELI’s electric forklifts can handle your toughest jobs quietly and emission free.
Take the HELI Challenge and see for yourself why more businesses are choosing HELI from Grant Handling.
