9 Best Practices for Forklift Fleet Management

Forklifts have evolved over the years, but the fundamentals of fleet management remain the same: proper maintenance and operational practices reduce downtime, lower costs, and extend equipment life. Here’s what you need to know:

How Long Does a Forklift Last?

• Average lifespan: 10,000 hours (about 5 years at 2,000 hours/year)
• Well-maintained forklifts can exceed 20,000 hours

9 Forklift Fleet Management Best Practices

1. Keep Accurate Records

Track each forklift’s purchase details, maintenance history, and engine hours. This helps identify trends and determine the right time for replacement.

2. Know Your Costs

Calculate ownership cost and maintenance cost per hour to avoid budget drains. Example:

• Ownership cost = (Purchase price – Trade-in value) ÷ Engine hours
• Maintenance cost = Total maintenance ÷ Engine hours

Don’t rely on age alone. Replace at the economic break-even point—when maintenance costs start to outweigh productivity.

4. Match Forklift to Application

Ensure your forklift specs fit your current warehouse layout and load requirements. A dealer audit can help optimize your fleet.

5. Perform Planned Maintenance

Follow manufacturer schedules to prevent costly repairs and downtime.

6. Read the Manual

Use recommended fluids and parts. Review safety and operation guidelines regularly.

7. Train Operators

OSHA requires forklift safety training. Proper training reduces damage, improves safety, and lowers costs.

8. Maintain a Clean Facility

Dust, debris, and uneven floors can damage forklifts and create hazards. Good housekeeping extends equipment life.

9. Partner with Your Dealer

Dealers can assist with audits, training, maintenance programs, and record keeping.