Posted by Thelma Marshall, Product Director, February 11, 2020

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What feeds the waste stream each day in your facility? Chances are there are more than a few warehouse secrets that reduce profits and make benchmarks goals impossible to achieve.

The solution is to identify what’s happening below surface level observation and address it. You already know that the largest portion of warehouse operating expenses are your forklifts, batteries, and forklift operators. And you may think you know all their details because you are watching them. But, your operation probably has several small procedural challenges that occur, yet go unnoticed.

What keeps these costly little issues secret? They are hidden at the granular level of day-to-day operations. They are the small challenges, the mishaps and omissions that are hard to track because managers can’t be watching everything at the same time.

Here’s what to do

Identify where money is lost each day. The easier your monitoring data is to read and understand the more likely you are to act on it. Leverage a platform that does the work for you then look at specific areas where waste hides.

Forklift expenses

Upfront costs for forklifts make them one of the most expensive equipment in your warehouse. But there are hidden ways that your fleet and operators are wasting time and money.

Risky behavior, near-miss incidents, damages

Often accidents happened due to human error. Small incidents and near misses can cost productivity, time and damage forklifts. Yet, these small incidents are not necessarily well documented.

Track all incidents that occur, in detail, for analysis in safety investigations.

Use it to get warnings about poor operator behavior patterns (an operator report card) and determine the root cause of accidents.

Poor maintenance of batteries & equipment

If maintenance is skipped to save time, it is really costing you. The fleet will be less efficient and more prone to breakdowns, impacts, or driver injury. The more repairs needed, the more money is spent on parts and servicing. Look at maintenance schedules and if repairs are being completed.

Poor care of batteries

Improper battery care and charging practices can end battery life prematurely. Look at how often opportunity charging occurs. This is a common hidden practice in many warehouse facilities but charging a battery too soon eats away at its lifespan. Batteries should also get fully recharged daily.

Telematic battery-monitoring technology tracks the status of each battery, including when and how it is being charged.

Inefficient routing

A poorly routed fleet adds up to costly inefficiencies. Real-time visibility into the movement and performance of your fleet can identify how to eliminate traffic and safety risks that slow down productivity.

Your telematics software platform can make it easy to uncover those smaller, yet costly, warehouse secrets, and help you to create a strategy to reduce hidden waste.

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