Moving from bulk leaf chain to pre-cut, ready-to-install assemblies can reduce workshop preparation, minimise material waste and help engineers get equipment back into service faster.
When a forklift requires a mast chain replacement, getting it safely back into operation is the priority. Yet replacing leaf chain can still involve a time-consuming preparation process.
Holding bulk reel stock and preparing chain in-house has traditionally been part of the workshop routine. But as service businesses face increasing pressure to improve technician productivity, reduce downtime and control costs, the wider impact of that approach is coming under closer scrutiny.
Where workshop hours are lost
Preparing leaf chain on-site involves several individual tasks. An engineer must establish the required length, count pitches, cut the chain using suitable equipment, prepare the cut ends and fit the necessary end fittings. FB Leaf Chain estimates that manual preparation can take around 30 to 45 minutes per set, depending on the application. Across a busy servicing schedule, that time can quickly add up, taking skilled engineers away from diagnostics, repairs and preventative maintenance.
There is also a material cost. Cutting from bulk reels can produce off-cuts that are unsuitable for future applications, turning purchased material into scrap while requiring additional stock to cover different chain lengths.
Safety, consistency and traceability
Leaf chain is a safety-critical component used in forklift masts and other demanding applications. Maintaining consistent quality and correct assembly is therefore essential.
In-house preparation introduces additional cutting and handling processes. Factory-controlled preparation provides a consistent alternative, with the chain supplied to specified lengths and, where required, assembled with the appropriate anchor components.
FB Leaf Chain also offers pre-lubricated assemblies and batch traceability, providing service operations with greater consistency and visibility from manufacture through to installation.
From workshop preparation to ready-to-install
For service operations, field engineers and OEMs, pre-prepared components offer a straightforward way to remove non-value-added work from the maintenance process.
Pre-cut assemblies arrive with the required length established before the component reaches the workshop or service vehicle. This removes the need for on-site pitch counting and cutting, allowing engineers to concentrate on installation and getting equipment operational.
The approach can also simplify stock management. Rather than holding bulk chain and accepting that some material will become unusable off-cuts, operations can order assemblies according to their specific requirements.
FB Leaf Chain has more than 40 years’ experience producing leaf chain for forklift manufacturers and replacement applications, with manufacturing and assembly carried out at its UK facility in Letchworth Garden City.
For operations looking to make better use of skilled engineering time, reduce material waste and streamline maintenance, moving from bulk chain preparation to ready-to-install assemblies offers a practical route to greater efficiency.
To find out more about FB Leaf Chain’s cut-to-length assemblies, visit www.leafchain.com or email sales@fbchain.com.
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