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Cranedge team conducted a thorough audit of all their cranes. Suggestions were made to the client, which proved greatly worthy.

Project highlights

Gestamp Automotive is an international group dedicated to the design, development and manufacture of metal components and structural systems for the automotive industry. Today, Gestamp Automotive is present in 22 countries and has 95 production centres (49 plants in West Europe, 15 plants in East Europe, 8 plants in North America, 9 plants in South America, 14 plants in Asia) and 13 R&D centres, and has over 25,000 employees. One such plant of Gestamp Automotive India is in Chakan, near Pune in India. This plant presently has 5 ElectroMech EOT cranes on their press shop, which are performing extremely well and to the satisfaction of the customer for the last 5 years. However, there was a change in the handling requirement due to an increase in the production and die maintenance activity.

The cranes being used presently are -

With the change in the production requirement and die maintenance activities, Gestamp required 2 cranes of 50/15MT in Line 1 bay. Hence, they approached Cranedge for their following requirements.

Based on the above enquiry, Cranedge evaluated the possibility of converting 32/16MT to 50/16MT crane and found that technically this modification was not feasible.

A completely new crane for Bay 2 was then considered, however this option proved to be beyond their allocated budget for this upgrade. The client approached Cranedge again for solving this problem. Looking at the challenge involved in the project, the Cranedge team decided to conduct a thorough audit of all the cranes on the shop-floor. A careful study of the optimum usage pattern revealed that the Blanking line 32/16t crane was not fully utilised and a 50/15t crane was not essential in Bay 3 (Line 2) as die handling demanded no more than 30t capacity. Hence, the following suggestions were made to the client.

The most interesting part of the proposal was that the entire investment in the project was just 40% of the cost of a new crane. The client was definitely impressed with this ingenious solution and opted for it. After making all the initial preparations, the required cranes were re-engineered and reallocation of cranes was done based on the client's requirement. This was quite a herculean task, but with the help of a large team of engineers and contractors we completed this task in just 6 days.

We sincerely thank team Gestamp Automotive India for involving us in this challenging project and trusting our solutions providing capability.