The information below has been reproduced ad verbatim from a fork tip impact study carried out by Kodak, you may download a PDF version of the original report to your computer by clicking here.
Opportunity
Between September 2006 and September 2007 there were a total of 168 forklift truck incidents causing damage to plates.
Following an extensive look into the recorded safety incidents and the scrap reports as well as talking to forklift drivers. It was realised that significant savings could be made by reducing the number of incidents involving damaged plates.
Change
Raising the awareness of forklift truck related incidents to all staff by team briefs, brainstorming / try-storming sessions, one to one training and Safetrack audits.
Understanding that it is not about how much WIP there is but how and where it is placed.
Implementing the fitment of fork tip protectors to help reduce plate damage caused by impacts.
FLT operator behaviour – Fork tip protectors require more accurate driving and in addition makes operators more aware of the tip, especially in yellow light areas.
Impact
Incidents involving damage to plates have been reduced by over 80%. This equates to a minimum saving of £150,000 and more than 9500m2. Intangible costs including rework, investigation time, part loaded vehicles are also greatly reduced. Due to the success of the trial area we will be fitting fork tip protectors to all suitable forklift trucks within the Leeds manufacturing plant.