Why Fork Arm Maintenance is Critical for Safety and Efficiency

Did you know that every year an average of 87 workplace deaths are caused by forklifts? These accidents happen for many reasons and unfortunately improper maintenance is often one of them. Forklifts are crucial tools on any worksite in almost every industry, from manufacturing to entertainment because of their ability to lift and transport heavy loads. Using the upward lift of fork arms, forklifts are able to carry their cargo from one place to another. 

With all of their heavy lifting around the worksite, it’s no wonder that keeping up on your forklift's maintenance is critical for the safety of your operation and workforce, but also ensures your day-to-day work continues to run efficiently. 

At ICHINEN USA, we manufacture standard and premium fork arms and fork arm accessories and have learned a lot about forklift safety along the way. In this blog, we are going to take a look at what could happen if you do not maintain your fork arms, how maintenance can drive operational efficiency, and some quick tips on fork arm maintenance.

Safety Risks of Undermaintained Fork Arms

OSHA regulations state it is important to perform regular maintenance according to the manufacturer’s scheduled recommendations, on top of daily pre-operation inspections. A forklift that is not properly maintained can pose the following safety risks:

Compromised Structural Integrity

• Cracks and Bends: Stress from daily use, bumps, and scrapes can lead to invisible (or hard-to-see) cracks and subtle bends, significantly weakening the fork arm.
• Wear and Tear: Thinning of the fork heel or blade and excessive tip wear reduce the fork's load-bearing capacity below its rated limit, making it unsafe for its intended use.
• Material Fatigue: Over time, repeated stress can weaken the metal, leading to sudden failure without obvious warning signs.

Load Instability and Dropped Loads

• Uneven Forks: Discrepancies in fork height or angle create an unstable platform, causing loads to shift, tip, or fall.
• Reduced Load Capacity: Worn forks cannot safely handle their rated weight, increasing the risk of load failure.
• Consequences: Damage to valuable inventory, surrounding equipment, and, most critically, potential injuries to personnel from falling loads.

Operator Injury and Fatality

• Direct Impact: Falling loads or overturning forklifts (due to load instability) can cause severe injuries or fatalities to operators and those nearby.
• Indirect Risks: Operators may compensate for faulty equipment, leading to fatigue, reduced focus, and increased accident likelihood.

Legal and Compliance Ramifications

• Regulatory Fines: Non-compliance with safety standards (e.g., OSHA regulations) due to neglected maintenance can result in hefty fines.
• Liability: Businesses face significant legal liability, potential lawsuits, and reputational damage in the event of accidents caused by faulty equipment.

How Maintenance Drives Efficiency

Beyond safety, proactive fork arm maintenance is a strategic investment that directly enhances operational efficiency, reduces costs, and maximizes your equipment's lifespan. When you ensure that your equipment is in good working order, you can expect many positive operational impacts.

Reduced Downtime

• Regular inspections catch minor issues before they escalate into major breakdowns, shifting from costly reactive repairs to more efficient preventative maintenance.
• Avoiding unexpected downtime means consistent operations, fewer production delays, and significant savings from not having forklifts out of commission.

Optimized Load Handling

• Properly maintained forks ensure a stable, secure grip on loads, minimizing slippage and enabling confident lifting.
• Operators spend less time adjusting unstable loads, leading to smoother, quicker picks and placements, and overall improved warehouse throughput.

Extended Equipment Lifespan

• Healthy fork arms reduce strain on other critical components like the mast and hydraulic system, preventing premature wear across the entire machine.
• Extending the operational life of your forklifts means getting more years of service from your initial investment, delaying costly equipment replacement.

Lower Operational Costs

• Addressing minor fork arm issues proactively prevents them from escalating into expensive, complex overhauls.
• Fewer dropped or mishandled loads directly translates to less wasted inventory and associated financial losses.
• A proactive maintenance approach contributes to lower insurance premiums (in some cases) and a more cost-effective, efficient operation.

Practical Fork Arm Maintenance Tips

Keeping up with your forklift maintenance doesn’t need to be complicated or interrupt your operation. With some intentional planning and scheduling, as well as careful handling by trained operators, maintaining a forklift fits right into any businesses day-to-day operations, no matter the industry. Consider these tips as you work your forklift’s maintenance into your schedule.

Regular Visual Inspections: Every forklift operator should inspect their equipment before use, looking for cracks, bends, wear and tear, and locking pins. They should also have access to a clear reporting system to identify any potential issues. No operator should attempt to operate a forklift that does not pass daily inspection.

Scheduled Maintenance: How frequently you maintain your forklift will depend on how often you use it and the manufacturer’s recommendations. It is important to schedule maintenance by professional technicians who are qualified to perform forklift maintenance. This way, you can rest assured that your equipment has been properly maintained and is ready to continue work.

Maintenance Checks: While it’s important to know how to tell if your fork arms need replacement, keep an eye on these specific areas of the fork arm to watch for maintenance opportunities:

• Fork Tip and Heel Wear
• Blade Straightness/Squareness
• Check for Top Hooks & Pins
• Fork Arm Angle/Levelness

Careful Handling: Ensuring that forklift operators are properly trained, adhere to capacity limits, and do their best to drive smoothly and avoid impacts will help you lower the likelihood that you will need to maintain or replace your fork arms.  Safe operating is the number one way to prevent unnecessary damage to fork arms and lower their maintenance needs. 

Prioritize Safety, Optimize Operations

Staying on top of your forklift’s maintenance will not only make your worksite safer, it will also increase your operation’s efficiency. At ICHINEN USA, we believe that everyone has a responsibility, from operators all the way to us, fork arm manufacturers, to be actively involved in prioritizing safety and efficiency. By participating in daily inspections, scheduling preventative maintenance, and knowing when a fork arm needs to be replaced, you can ensure safety remains top of mind today, preventing major problems tomorrow.

If you have a forklift that needs replacement fork arms or fork arm accessories, contact us to learn which fork arm fits your unique lifting needs!