Gripping Forks

David Priestman met with an Australian manufacturer of forks and forklift safety products celebrating its 10th anniversary.

GenieGrips, based in Melbourne, launched a prototype product at a trade show a decade ago. “Fifty people said, ‘we need those’,” Director Louise Inglese tells me. So they set to work, initially with self-adhesive stick pads for forks, made from disposable rubber, that prevent scratching the stainless steel.

The company’s launch in the UK was in 2019. This was hampered by the pandemic causing the cessation of trade shows – which are key for new business generation for GenieGrips. IMHX Birmingham in September 2022 was therefore a relaunch and Inglese is delighted that exhibitions are back.

It is a family-owned firm, with Louise’s husband Michael providing the engineering expertise. Together they spun the company out of CRP Industries, with specialist capability in bonding rubber to metal. “We get customer feedback regarding pain points in managing their forklifts,” Louise Inglese explains, “which leads us to invent and make new products.” For example, the company now offers mats with adjustable hooks, rather than static.

GenieGrips offers 5 product ranges:

· Mats – the top seller, available in various lengths and widths
· Caps – for protecting the tips of forks
· Cushions – which are attached vertically to the uprights of the forks
· Sticker Pads – adhesive, 8 in a box
· Loading Mirrors – acrylic, reflective and adjustable to provide a wide or slim view so that the driver can see in front of the load when loading and unloading (bulky loads obscure the view)

There are about 20 distributors worldwide, including TVH (exclusively so in Mexico). GenieGrips also supplies products to OEMs, including fork attachment suppliers like B&B and forklift manufacturers like Crown and Hyster-Yale, for sale to the final customer, if requested. The products’ good reputation leads to high re-order rates. Keith Waterman runs the British subsidiary. He tells me: “Since having been given the opportunity to promote and distribute this great product customers are showing a lot of interest in GenieGrips, which helps and makes the job a lot easier. The feedback from customers is always positive, no matter what they are moving.

Fork coverings

“Our website is having a lot of interest with existing customers ordering more products to put on the rest of their fleet of FLT’s, which is always satisfying. My ambition is to see the bright yellow fork coverings and loading mirrors on all FLT’s across the country, knowing that the work place is a safer environment and that companies are also protecting their products and reaping the financial rewards too. And what’s better is representing and working for a wonderful team at GenieGrips.

The mission of Genie Grips is to improve safety in working environments throughout the world with their high-quality range. To achieve that goal in Europe, they decided to cooperate with C&H Maastricht, based in south-east Netherlands. The official European introduction happened during LogiMAT 2018 in Stuttgart. C&H Maastricht executed a pre-exhibition marketing strategy to inform the market of their presence at the show. This resulted in interest and orders from all over the world, giving GenieGrips a successful foothold on the European market. Now, C&H Maastricht operates as the European Sales Support Office and official agent for GenieGrips in Europe.

What of the next steps for the company? Louise Inglese: “We strive for continual improvement. Over the next six months there will be a release of the GenieGrips® Mats and Cushions with new and improved features. We design our products with convenience in mind so that our customers can remain active and profitable. Even though, as an Australian business, we believe in producing our products with the highest standard possible, we endeavour to keep our products affordable and relevant.”

Fatigued operators are 7.3x greater accident risk

A 2013 study by the US Department of Transportation (US DoT) is receiving newfound attention, due to the recent release of ReadiML, the Machine Learning software from Fatigue Science that operationalises a scientific fatigue prediction model for daily use by transportation fleets.

In the study, the US DoT determined that when locomotive engineers are predicted by the scientific model to be severely fatigued, those operators carry an accident cost exposure that is over 7 times higher than it is for non-fatigued operators.

Key to this story is that “fatigue” could be predicted in advance of actual vehicle operation – unlocking the opportunity for proactive measures within dispatch operations to pinpoint and avert severe risks before they happen.

The US DoT study, Fatigue Status of the US Railroad Industry, used data collected in the railroad industry in the US between 2003 and 2005. Within the dataset, logs from 731 unique human factors accidents (HFAs) were compared to the predicted fatigue level of each operator. Fatigue predictions were derived using the SAFTE Biomathematical Fatigue Model, which analysed assumptions of operators’ sleep in the days preceding each sleep period. These assumptions were based on the periods of sleep opportunity afforded by each operator’s work hours.

Greater risk from fatigued operators

The analysis revealed the probability of a human factors accident (HFA) per 200,000 employee-hours, in cases with severe fatigue and, separately, in cases where no fatigue was present. In cases of severe fatigue – when the operator’s SAFTE Effectiveness Score was below 50 – the probability was 0.276. (The SAFTE Effectiveness Score is now known as the ReadiScore). In contrast, in cases without fatigue (ReadiScore >90), the HFA probability was only 0.152.

The risk of an HFA was thus 1.82x higher when severe fatigue was predicted by the model – nearly double.

Moreover, the study revealed a significant difference in accident cost between those that occurred under various levels of fatigue. Railroad accidents with a fatigued operator (ReadiScore <70) presented an average cost of $1.6m, in contrast to only a $400,000 average cost when no fatigue (ReadiScore >90) was predicted.

It is not known how much larger than $1.6m the average accident cost would be for the subset of fatigue cases classified as “extreme” (ReadiScore <50), but it is reasonable to assume that the cost would likely be even higher than the larger pool of fatigued cases (ReadiScore <70).

With the conservative assumption that accidents from “extreme fatigue” were no more costly than those from merely “high fatigue”, the implication is clear: fatigue-related accidents cost at least four times more, on average, than non-fatigue related accidents.

Combining the statistics on accident probability and accident cost, the result is at least a 7.3x higher accident cost exposure when operating critically fatigued (ReadiScore <50), as compared to operating without fatigue.

Subscribe

Get notified about New Episodes of our Podcast, New Magazine Issues and stay updated with our Weekly Newsletter.