There is a crisis brewing in the factory and no one is aware that the production line could be shut down at any moment. The consequences would be severe if that happens. Production has been working at capacity three shifts a day, seven days a week for months. At risk are unrecoverable lost production and wages, not mention the customer who is waiting at the other end and is depending on shipped products to keep his business going.

Overhead cranes are often forgotten. Plant managers are saddled with the responsibility to keep everything going. Production rules the day. Communication with purchasing, quality control, production, and maintenance departments and many others is the key to control events so that production stays on schedule. Overhead cranes are constantly feeding the required materials through the manufacturing process. What measures should be taken to ensure that they remain the reliable tool that is so critical for the plant operations?According to OHSA and industry standards, the minimum number of inspections required for overhead cranes and hoists is once a year. These should be increased depending on the age and duty requirements of the crane. Factors such as frequency of use, cycling and the average weight carried need to be considered. To insure their continued reliability an experienced technician will take at least two to three hours to complete an inspection for an average manufacturing duty crane. Items that he will be looking at include:

Brakes for all three motions, which should be checked, changed and/or adjusted as required

Wire rope should be properly lubricated and need to be reviewed for stretching, kinks, core and strand deterioration.

The wire rope should be seated in their proper grooves on the drum. The drum should be inspected for wear.

Wire rope needs to be in its proper position on the drum, the rope guide, in many cases, serves to activate the upper and lower limit switches that must be checked for functionality.

Sheaves should not have any corrugation in the slots and the wire rope should fall into position smoothly and evenly.

No deterioration should be evident on the bottom block and hook, including the safety latch.

Hoist and trolley motors and gearboxes need to be checked for leaks, wear or deterioration.

Wheels and bearings require the service technician’s attention. Excessive wear might indicate a change up is in order

Electrical, power feed collectors, wiring and conductors should be checked for wear or abuse.

Cracked pendent control casings, worn or deteriorated control buttons are a common problem that requires attention.

The control panel should be checked, the starters and their contacts the tolerance for wear. Welding of the contacts can lead to “two blocking” which is very dangerous and can be extremely costly.

However, the first line of defense is proper training of crane and hoist operators. They must be able to detect imminent equipment problems. Indicators that the hoist or other vital components are about to fail must be recognized. The cost to provide operators with the knowledge that minimizes the risk of production stoppage are small compared to the alternative. Increased safety and decreased down time can easily justify the expense.

Considering the hard work and critical nature of the overhead equipment to keep the factory producing they should be allowed regular inspections. Just like other production equipment these need their proper attention.

copyright Joe Harnest
Crane Training Canada
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Tying up a forklift or overhead crane for an individual workstation on a regular basis may not be practical. Lifting, turning or positioning material to suit individual applications can be accomplished win a variety of ways. Jib cranes, gantry cranes and manufactured track systems can be a relatively low cost alternative to resolve these problems.

A very versatile machine, jib cranes can be mounted to existing columns or they can be floor mounted for a free-standing solution for your work application. Low headroom jib cranes are designed to fit into height restricted areas, allowing overhead cranes to pass without restriction. Capacities range from 50 lbs. to 25 tons and booms can be manufactured to rotate 360 degrees continuously or with stops to restrict the rotation as required.

The boom length is limited to the demands of the application. The column or footing required, depending on the style of jib selected, must be designed to accommodate the dynamic forces created by the loaded jib. Another option is a suspended track system, which can be attached to existing building steel or can be supplied free-standing, with columns and structure.

A feature of these systems is their ease of material movement with an unconfined space. Usually equipped with hardened plastic wheels that ran inside a manufactured tract, the materials they are carrying seem to float with a minimum of resistance. These are normally used in applications that demand capacities under two tons and spans of twenty-five feet or less.

The floor running gantry crane presents yet another alternatives to assist workstation material handling. They are probably the lowest cost option. Gantry cranes require additional floor space which must be kept clear to allow movement, but are unrestricted to go anywhere the floor conditions permit. These are available with motorized bridge travel wheels in all capacities and spans. These have been supplied with a steerable mechanism for the complete flexibility required by the application.

The above are all normally used in conjunction with hoists and trolleys and become more practical when supplied with special grabs and adapters for the handling of specific items. Utilizing manual, electric or air power, they are a sound solution when safety and productivity are important.

copyright Joe Harnest
Crane Training Canada
www.cranetraining.ca
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I enjoy watching athletic events, such as the Olympics and seeing events unfolding to see who will be recognized as the best. The one detractor from my enjoyment of some athletic events is the endless commentary.

The field of material handling is a very competitive one. From overhead cranes to conveyor systems, competing manufacturers have produced an array of equipment that present specific values to potential buyers. The variety of competitors offering similar products can challenge the most discriminating buyer.I have found too often, that the lowest price is the only determining factor in a purchasing decision. The buyer has assumed that all competitors are equal, but the fact is, they rarely are. Is it a worthwhile practice for buyers to ask, “what is the difference between yours and other equipment?” You might be surprised at the response.

It is understandable that cost must be part of the equation. Value, however, should be the primary determining factor in a purchase. Cost is a shallow representation of the competitors. It is up to the buyer to evaluate each product based on duty cycling capability, efficiency, reliability, user friendliness, safety and vital criteria. The significance of long term performance and reliability may outweigh, by far, the short term savings that are apparent at first blush.

Just as athletes must have everything absolutely right to achieve their goal, so does your company. If you want to stand on the podium with the ultimate prize, invest your time in a little homework.

copyright Joe Harnest
Crane Training Canada
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