Forklift Downtime Costs: Guide

You know the drill. A forklift goes down, and suddenly everything’s behind. Orders back up. Crew’s stuck waiting. Tension rises. It’s a headache.

But the real issue isn’t just the broken machine. It’s what the downtime does to your operation. Slower output. Missed deliveries. Extra labor costs. It adds up faster than most folks think.

A single breakdown can throw off your whole day, maybe longer. And when it happens more than once, you start to feel it in your bottom line.

Forklift downtime costs: It’s Not Just the Cost of a Repair

You fix the forklift. Maybe you rent a backup. Problem solved, right?

Not really.

Every hour that forklift isn’t running, you’re paying for:

• Labor with less output

• Delays in picking, packing, or loading

• Missed delivery windows

• Scrambling to rent equipment last-minute

• Overtime just to catch up

And that’s not even counting the pressure it puts on the rest of your crew. Or how much strain it puts on your other machines when they’re pushed harder to make up for the one that’s out.

What Causes Downtime?

In most cases, it’s not some major failure out of nowhere. It’s usually something that could have been caught earlier.

• Missed maintenance checks

• Low fluid levels or dirty filters

• Worn-out tires, hoses, or forks

• Weak batteries

• Equipment that’s past its service life

Often, the signs are there. A slow lift, a strange sound, a warning light that gets ignored. But the job needs to get done, so it keeps running, until it doesn’t.

How to Stay Ahead of Unexpected Forklift Downtime Costs

You don’t need a brand-new fleet to stay on track. You just need a plan.

Stick to a maintenance schedule

Regular checkups prevent most breakdowns. Even something as simple as checking fluid levels or replacing worn parts can keep a forklift running longer.

Thompson Lift Truck offers maintenance plans that fit your workload and your schedule, so downtime stays off your calendar.

Track your service history

When you know how often a machine’s in the shop, it’s easier to see when it’s time to replace it, or step up maintenance. Patterns always show up if you’re looking.

Train your team to flag problems early

Operators should know what to look for during daily checks. If they catch something small before it turns into a major failure, you’ve already saved time and money.

Forklift Rentals That Keep Work Moving

A rental forklift isn’t just a backup. It’s a lifeline when something breaks down mid-shift or demand suddenly spikes.

We carry electric, propane, diesel, and narrow aisle models, ready for short- or long-term rental. Every unit is fully serviced before delivery, so you can put it to work the minute it arrives.

Let us know what you need and how long you need it. We’ll handle the rest.

Why Choose Thompson Lift Truck?

Operations managers across the Southeast work with us because we help them stay ahead of downtime, not just react to it.

• Preventive maintenance built around your operation

• Quick, reliable field service when things go wrong

• A wide selection of forklifts ready to rent

• Trusted brands like Crown, Hyundai, and Combilift

We get it. You need solutions that keep your crew moving and your schedule on track. We’re here to help make that happen.

Talk to a Thompson Expert

Want to avoid costly downtime? Talk to Thompson Lift Truck about maintenance plans, on-site repairs, and rental support that keeps your operation moving.
Contact us today to get started.