Lift off

Those once pristine forks are now sullied with scuff marks. A cab door that was not so long ago clean enough to eat your dinner off has become a dog's dinner of dents and divots. And that hi tech hydraulic lifting system now groans like an old immersion heater. If your trusty forklift matches any of the descriptions above then 2014 might just be the year to replace. Factory order books are already up 76% on November 2012 according to WM's Outlook research and 85% of frontline managers are bullish over sustained business success next year. That translates to a whole lot more lifting, loading and ferrying for your fading forklift. "As we're coming out of recession, people are going to get very high demands on productivity," says Russell Baker, territory manager for Hyster Europe. "The more considered managers know the cost of a wrong decision. If you have to stop a production line because of a problem with a fork lift then that's going to have a big impact." With your mind made up to replace, the next conundrum is whether to buy new or used. New trucks offer the latest spec, enhanced reliability and full servicing packages. New models are best suited to factories that are fanatical fork lift trucks users. That translates as at least four hours' continuous operation a day. If your site's in that bracket then the operating and maintenance savings from renting or buying brand new are likely to pay back over the months and years of its use. Go new and you can expect to be in the box seat when it comes to clinching a deal with the truck manufacturer. Forklift sales have still to recover from pre-recession levels and, despite a projected 0.7% uplift this year, it remains a buyer's market. "Over the last three or four years, the forklift industry has appreciated there's a lot of uncertainty out there for customers," says Baker. "We've responded to that by offering more flexibility in finance packages." Hire contracts have extended from five to seven years and beyond. Free rental periods are also entwined into hire packages to entice factory managers. Before you do put pen to paper though it's absolutely essential to check your dream machine won't be giving you nightmares down the line says Baker. "My advice to anyone looking to buy is to consider what your demand is going to be over the next five years. It's a long commitment and as we're starting to come out of recession; it's important you don't just replace what you have." The second hand market is Mecca for less intensive fork lift users or those who just can't resist the allure of a bargain. And there are plenty out there for seasoned tyre kickers. Major manufacturers like Toyota Material Handling, Jungheinrich and Hyster, via Briggs Equipment, all cater for the used market. Models include those cherry picked from contract hire fleets, giving the buyer the confidence that the truck has been lovingly maintained. "I could offer you a truck at £9,000 and you could say: 'Well, the guy down the road is offering me a similar machine for £6,000'," says John Murphy of Briggs Equipment. "But how old is that machine? Can the age be proved? What are the hours and have they got an engine serial number?" The used truck market is ripe with examples of mutton dressed as lamb, says Murphy. "You can buy a refurbished truck for a seemingly bargain price. It's had a re spray and, on first impressions, it looks nice. But you can end up paying over the odds for a 10-year old truck." Buying used doesn't mean bringing a cash-stashed suitcase to the showroom. Dealers offer finance packages to ease upfront purchase costs and will part exchange on your current trucks. Warranty and service packages are also available to used equipment buyers. These are well worth stretching the budget for as they will protect you against hidden expenses like new truck batteries. Whether you go for new or used in 2014 will be about what's best for your site. But, whichever route you decide to take, it's worth remembering one universal tip to make it a happy New Year for your materials handling fleet. "It pays to go and take a look around the truck," advises Murphy. "Check it's been properly prepared – are there dents or damage? If it's new, then check the space is what you thought? It's like going to look at a BMW 3 Series and realising: 'It's bigger than I thought'." As with so many aspects of running a successful factory, there's nothing to beat a bit of gemba. "Driver input is essential," says Derek Robson , general manager at Nissan Forklift. "A satisfied operator working in an ergonomic and safe truck almost always increases productivity and reduces damage." "It's important the buyer gets in or brings one of his drivers to try it," agrees Baker. "The drivers who will be using the truck often spot something the buyer won't. You might want to rein them in when they start asking if it comes with stereo though." What to look out for on the forecourt Visibility: Cabs should offer unrestricted view and be free of blindspots Mast height: The truck must be able to reach the top racks, but not so tall that it takes out your sprinkler system in the process. Check the ratio of closed to top lift height and the hydraulic power system is performing well Bodywork: Don't let a new paint job mask tell-tale scrapes and dents. Check out overhead guards. Any damage here will compromise safety. With new guards costing several thousand pounds, a close once-over on the forecourt will pay dividends down the line Engine: Diesel, gas, electric or hybrid – your decision should be based on your typical use demands and price (running costs as well as purchase). Ask a dealer for more guidance. Whatever fuel type you opt for, lift up the seat and take a look at the engine's condition. Remember to start her up and listen out for signs of strain Battery: Replacing a fork lift battery will set you back a whole lot more than a pack of AAs. On electric trucks, the battery can account for 30-40% of the truck's overall value. Antiquated batteries will sap performance and restrict run times to just a few hours. Ask the seller for a service history and be guided by the truck's hours Tyres: Just because your forklift's daily duties can be clocked in yards rather than miles, it doesn't mean you should scrimp on tyres. The right tyre will improve fuel efficiency, performance and safety. There are two main types: Solid tyres (resilient or press-on band) for internal use and pneumatic (air-filled) for greater suspension and outdoor use. It's worth stretching to a premium tyre whatever you go with – it will last longer and boost truck performance. Always push for a fresh set from the seller before shaking on the deal Seat: The seat has as much say over your truck's performance spec as the horse power. Drivers are going to be sitting in it all day so a piles-inducing perch is going to damage productivity. Go for something which offers comfort and adjustability to suit the individual driver's preferences. Bring the driver along and get their opinion Accessories: Make sure your fork lift truck is easy for operators to spot by equipping it with good lighting and reflective stickers. Hi-vis PPE is mandatory for drivers. Luminous lucky safety dice are optional Load capacity: It's not just the total weight of your load that matters, but also its dimensions. The forklift's ability to lift its max weight will depend on the size of your load centre. Loads that are higher or wider will cause extra stress and strain. The best bet is to take your sums long with you on viewing Forks: Inspect the forks for damage and fit. A loose fit could indicate a worn carriage. Cracks in the fork could be a safety risk. Forks are deemed safe until they reach 10% wear Size: It's no good splashing out on the Ferrari of forklift trucks if you can't squeeze it down aisle 11 to pick up spare pallets. Check your dream machine is compatible with your factory dimensions or you could be left with some very unsightly go-faster stripes. Going for a bigger truck may also require extra driver training. Old passing points may quickly become accident hotspots unless your employees get their heads around the new truck's expanded dimensions Hour meter: Every 1,000 hours on the forklift clock is equivalent to 30,000 miles on your car according to experts. Remember that when your seller is waxing lyrical about the year of manufacture. You're just as well looking at a slightly older model with a lower 'mileage' than a 2012 plate that's seen more use than the factory kettle