New Versus Refurbished Forklifts
Every industry has its accepted truths. These are the things that everybody knows - the obvious answers. The problem is that yesterday’s truths may be out of date, and things that appear to be common sense on the surface may be a lot more complicated when you look a little deeper. When the question is a potentially expensive one like the purchase and maintenance of your forklift fleet, it’s a good idea to examine both possibilities.
Most operations that run a large fleet of forklifts select a primary new truck manufacturer (for example, Toyota or Hyster for pneumatic/cushion trucks, Crown or Raymond for electrics). It’s more convenient, dealing with a single company when arranging purchase or lease agreements, but that is not the primary consideration.
Full service leases are supposed to cover maintenance costs up front. Ideally, they allow you to plan maintenance schedules and costs, and then forget about it for the duration of the lease. There are two problems with this pretty picture. For one thing, most full service leases do not cover repair costs on the failure of components that are out of factory warranty, or on the failure of wear items such as brakes, etc.
Not all forklift manufacturers like Caterpillar, Hyster, Ford etc are good at everything that a forklift does in your operation. There are just too many variables. Electrics are quiet, inexpensive and nonpolluting, but of limited range. In some narrow aisle warehouse applications, turning radius can become a major consideration. In extreme cases, turret trucks may be required.
To get the most efficient vehicle for every job, you would have to determine the features and characteristics required for that job, and then buy the necessary number of trucks from the manufacturer who makes the best forklift with those features and characteristics - and then repeat the process for every job in your operation. A multi-location facility could easily end up with four or five different makes of lift truck. Remember, you are still only using one brand of fork lift for a given task, and because you have selected the brand with the best performance for that function, your maintenance for that brand is likely to go down.
Keeping a larger inventory of parts may cost a little more to begin with, but maintaining that inventory over time should result in no significant additional expense. As for training, it may be possible to specialize there as well.
Another accepted truth that may no longer be true is that refurbished forklift trucks, while less expensive than new ones, are less reliable and therefore not a good investment.
With the ever-increasing costs of capital equipment, refurbishing used lift trucks has finally become big business. Only a few years ago, the market for reconditioned forklifts wasn’t big enough to justify the expense of setting up an assembly line to tear down, inspect and re-assemble a vehicle with enough quality control to insure reliable operation in heavy use conditions.
The term refurbished means different things to different people. Before you even consider this option, make certain that the unit has been disassembled to the bare frame, sandblasted, painted and rebuilt. Even the engines should be completely broken down, refurbished and repainted to work and look like new. Purchasing used forklifts can be risky, but buying quality refurbished ones doesn’t have to be.
Renewed vehicles have had some run time, a kind of shakedown cruise after which the weak components are replaced. The result is a more reliable unit. Obviously, a refurbished truck has less of its reliable service life left than a new one, but consider the following scenario. You purchase a refurbished unit at one third the cost of a new one. You have already skipped the first wave of high maintenance cost that occurs during the run-in phase. You maintain it regularly and retire it perhaps a year earlier than you would a new unit, thus avoiding the last stage of high maintenance as it nears the end of its useful life. You have saved considerably in terms of capital investment, and your maintenance costs may actually go down as well.
