Forklift Fleet Optimisation: How to Reduce Costs and Improve Efficiency
Introduction
Managing a forklift fleet is about more than just keeping trucks on the floor — it’s about running them efficiently. Yet many businesses still ask the same question:
Do we have the right number of forklifts?
Running too few forklifts leads to delays and downtime. Running too many means wasted capital, higher maintenance bills, and lower utilisation. The solution lies in forklift fleet optimisation — a data-driven way to right-size your fleet.
That’s exactly why we created our free Forklift Fleet Optimiser Tool — to help businesses like yours find the balance between cost and performance.
Try the Free Forklift Fleet Optimiser Tool
What Is Forklift Fleet Optimisation?
Forklift fleet optimisation is the process of ensuring you have the right number of forklifts to meet operational demand at the lowest possible cost. It’s about:
Matching supply (trucks) to demand (throughput and workload)
Reducing downtime by improving utilisation
Minimising waste from underused or excess equipment
Improving overall warehouse efficiency
When done correctly, fleet optimisation can save companies thousands of pounds annually.
Why Is Forklift Fleet Optimisation Important?
According to the British Industrial Truck Association (BITA), the lifetime cost of a forklift can far exceed its purchase price once maintenance, fuel, and insurance are included. Add in downtime or underutilisation, and the costs spiral.
Benefits of forklift fleet optimisation include:
Lower operating costs
Improved productivity
Reduced accident risks (see HSE forklift safety guidance)
A leaner, more sustainable operation
Signs You Need to Optimise Your Forklift Fleet
Not sure if you’re running your fleet efficiently? Here are some red flags:
Forklifts sitting idle for long periods
Overtime or delays because not enough trucks are available
High maintenance bills on underutilised machines
Peaks and troughs in demand leaving fleets overstretched or underused
Unpredictable fleet budgets
If these sound familiar, your fleet could be too big, too small, or simply mismanaged.
How to Optimise Your Forklift Fleet (Step by Step)
1. Assess Current Fleet Utilisation
Measure how many forklifts are in use, how often, and for how long. Telematics data can help spot idle equipment.
2. Align Fleet Size with Demand
Forecast throughput and workforce needs. This prevents overcapacity (wasted costs) or undercapacity (delays).
3. Evaluate Total Cost of Ownership (TCO)
Factor in leasing costs, fuel, maintenance, insurance, and downtime. This gives you a true picture of cost per truck.
4. Plan for Peaks and Seasonality
Use short-term rentals or leasing options to handle demand spikes without committing to permanent purchases.
5. Use Fleet Management Tools
Our Fleet Optimiser Tool makes it easy to calculate the right number of forklifts for your operation in minutes.
Industry Trends Driving Smarter Forklift Fleet Management
At IMHX 2025, industry leaders highlighted three major forces shaping forklift fleet decisions:
Rising Costs: Businesses must extract more value from every asset.
Sustainability Goals: Leaner fleets mean lower energy consumption and emissions.
Data-Driven Decisions: Companies using analytics for fleet management consistently outperform those relying on guesswork.
External Resources for Further Reading
These trusted organisations provide additional insights into forklift safety, cost control, and operational efficiency.
Conclusion: Take Control of Your Fleet Today
Forklift fleet optimisation is about finding the sweet spot — not too many, not too few, but just right.
With the right data, tools, and strategy, you can:
Cut costs
Boost efficiency
Improve safety
Build a fleet that grows with your business
Start with our Free Forklift Fleet Optimiser Tool
It only takes a few minutes — but the savings could last for years.
