Preventing Forklift-Caused Product Damage in the Warehouse


Working with our industrial and warehousing clients, we know that product damage can be a costly problem. Damaged products result directly in financial losses, and indirectly in consumer unhappiness when the damaged product reaches the customer. Many businesses seem to accept a somewhat high level of product damage as being part of the cost of doing business, but it seemed to us there could be more education on this topic.

We set out to research the common ways products are damaged by forklifts in a warehouse environment. This is obviously a pretty wide topic to tackle, just due to the diversity of product types, forklifts, and warehouses. So we submitted a questionnaire to several warehousing experts and warehouse managers to try to whittle down the list of product-damaging incidents to those that applied to as many locations as possible.

The result, one year later, is Forklifts: Reducing Product Damage, a unique course that addresses the reasons behind most forklift-caused product damage. Some of the major mistakes covered include:

  • Insufficient fork spread
  • Insufficient fork depth
  • Load instability
  • Momentum-caused tipping
  • Rack placement damage
  • Stabbing and raking of product
  • Operator over-confidence

This course is intended as an introductory course for new warehouse workers, or as a refresher course for experienced drivers. As far as we know, this is the only training course that exists on this subject, and we’re proud to bring such a unique title to the market.

Thanks to the following warehouse/forklift experts who helped us with our research and gave us feedback on our course ideas:

  • Frederick “Rick” Heath: Material handling expert witness in Louisville, KY
  • Bill Guiher of Inflection Point in Cincinnati, OH
  • Don Benson of Warehouse Dashboard, LLC in Portland, OR
  • Dave Schneider: Logistics and supply chain consultant in Fairfax, VA
  • Frank Renshaw: Material handling expert in Florida
  • Daniel Vincent Byrne of ByrneInvent, LLC in Seattle, WA
  • Robert Footlik of Footlik & Associates, Evanston, Illinois

Check out a clip from the new video:

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