At the end of this module, you will be able to:
- List common causes of damaged product due to forklift handling (19 causes explained and how to avoid)
- Describe behaviors to reduce product damage from forklifts
The following key questions are answered in this module:
How big a problem is product damage?
Product damage is often a bigger problem than people realize. The cost includes the cost of inventory due to the product damage but the discovered product damage is only a fraction of the problem. The more serious problem is the unrecorded or unnoticed product damage that the customer ends up seeing. The unnoticed product damage has a serious effect on your company's relationship with its customers and can lead to a negative perception of the company's brand.
What are some common causes of product damage?
Damaged products are usually the result of pre-existing product damage received from a manufacturer or third-party delivery, an operator's view was obstructed by the load or forklift, an unstable load, or an operator was unfocused or distracted.
How do I avoid receiving damaged products that are delivered by a third-party or manufacturer?
It is important to perform a detailed inspection of deliveries from a third-party before the carrier leaves because this is usually the last chance to hold the third-party responsible for damage.
What is involved in the regular conveyor inspection?
Before inspecting a conveyor follow your facility's lockout Tagout procedure to safely shut down the conveyor. Inspect the entire conveyor before start-up. Inspect and test alarms, emergency stops, and guards. Also inspect for unusual noises or vibrations, unexpected changes in speed, and improper belt tension.
Below is a transcript of the video sample provided for this module:
Stabbing can result from having the forks extended too far out of a load. This can happen at floor level when first approaching a stack, or higher up, when placing the products in the stack. As stated earlier, if you don't know where your forks are, get out of the cab and take a look. Stabbing can also result from the practice of pushing a pallet into place using the fork tips. Never use the forks to slide a product into place. Always lift the load to reposition it. Stabbing can also occur after raising the forks up for stacking or destacking. With some forklifts, if the operator does not throttle down all the way after using the vertical lift, and then puts the forklift into forward motion, the forklift can jerk forward and stab product.
Use the additional resources and links below to learn more about this topic:
- Material Handling & Logistics – www.mhlnews.com
- MH&L Stop Load Damage - http://mhlnews.com/technology-amp-automation/stop-load-damage
- Decision Sciences Institute - www.decisionsciences.org
- Case study - http://www.decisionsciences.org/Proceedings/DSI2008/docs/461-9660.pdf