Cranedge Resonates Shop-floor Safety!

by admin_bbt_cranedge

Workplace safety is of utmost importance for any assembly unit. Every company tries to eliminate hazards by implementing HSE policies which safeguard the workers & operators on the shop floor. However, the employees must also take care of their safety and adhere to the safety rules laid down by the company. Generally, all industries design their safety guidelines in order to minimize the risk of injury to the stakeholders, may it be customers for factory visit, workers, operators or staff members. What they miss is the regular servicing and checking of the equipment they work with. Accidents that might take place on a shop floor, could be due to improper usage of equipment or due to low maintenance of equipments. 

However, sometimes it also happens that in spite of good maintenance, certain equipments with old or obsolete technology, tends to pose a great threat to the safety of the shop floor. Such equipment not only require good health check-up, but also requires upgrade to newer parts and upkeep with additional enhancers to make work with other modern requirements. Below is one such incident, which explains why safety should be a priority on the shop floor:

Case Study

One of the largest vehicle manufacturers in India well-known for its range of passenger vehicles and tractors faced a security threat in one of its manufacturing facilities near Pune. The plant oversees manufacturing of heavy parts required in the vehicles and operates in 3 shifts. This plant, being set up in the initial years of the company’s operations still continues to use older machinery and equipment for their material handling needs.

One day, during routine operations, a heavy load was being handled using one of their older cranes, when suddenly, the load slipped off and fell from a height of 5.5 meters. Fortunately, there were no casualties, but serious damage was caused to the machinery & the floor which resulted in financial and operational losses. The incident sent immediate ripples within the plant and the issue was informed to plant heads of different units, to take due diligence. This also shook the corporates office as the crane posed a real threat to the shop-floor safety. It was high time for a company, which is known for the its adherence to the highest level of safety standards, took the incident very seriously. A thorough probe was initiated and immediate “why why” analysis was done to find the causes of this mishap and it was decided to consult industry experts. That’s when Cranedge was called in to investigate the accident, suggest as well as implement a foolproof solution as well as under-take health check-ups for other cranes, not only for Pune plant but also for other plants across India. 

Our Solution

The Cranedge team of specialists visited the plant to investigate the cause for the incident. Their preliminary investigation revealed that it was due to failure of the hoisting brake and that it had no contingency measures.  Just to be on the safer side, our team conducted a thorough Health Check-up of the entire crane with structural analysis (FEA) of the main girders and other visual & functional diagnosis.

A complete report on the present condition of every major component of the crane was submitted to the customer along with our recommendations for additional features to ensure higher levels of safety. The additional features included:

  • Variable Frequency Drive (VFD): The existing crane being used of older technology; it had slipring motors on existing hoisting machinery. Today, the industry has advanced, and the slipring motor (being almost obsolete) has its own limitations as against the combination of squirrel cage motor and a VFD that offers better control. VFD being more energy efficient, also helps in reducing energy consumption. Considering these aspects, Cranedge modified the hoisting machinery by replacing the slipring motors with a new squirrel cage motor and VFD’s in electrical circuits.
  • Anti-fall System – In case the main brake fails, the crane’s electrical system will immediately trigger as it will detect load free fall and deploy counter measures. Here, the motor will give a reverse torque to uphold the load for few mins by assistance of the VFD. The system also automatically triggers a siren warning to the operator and the people in the vicinity are well informed about the emergency situation. Furthermore, it was suggested to the client that for certain select, critical application cranes, an “emergency brake” could also to be deployed. This critical time interval allows the operator to safely lower and park the load at a safe location. 
  • New Control Panel and Drag Chains – The crane was upgraded with completely new electrical panel housing and VFD’s along with encoders and other circuitry controls alongwith a new robust drag chain system.

Thus, Cranedge provided a quick diagnosis of the problem and a viable techno-commercial solution to the manufacturing plant and instilled a sense of assurance within the stakeholders about the safe operation of the crane in the future. For more such servicing solutions for your cranes, visit https://www.cranedge.com/

We Do Our Best for a Business Facing a Crane Distress!

by admin_bbt_cranedge

We are sure that most of you must have heard of the tragic incidence of Ethiopian airlines which crashed in 2019. Now, we are not going into the scrutiny of the incidence but taking it as a reference to express the importance of a “distress situation”. Some authorities and agencies had published that, the pilots had made a distress signal from the plane, and they were re-directed to land back by the Air traffic controller. The pilots didn’t get enough time to land the plane safely and unfortunately, a lot of lives were lost.

So, what exactly is a distress signal or a situation? A distress situation is a condition of being threatened by an imminent danger and calls for immediate assistance. A distress call takes utmost priority and should be handled by a person of authority and worked upon by specialists.

When it comes to material handling equipments like cranes, it is important that any such distress signals from the operators or maintenance teams should not go neglected. Cranedge was born out of such a commitment of attending any such material handling distress calls for any crane, any brand, anywhere around the globe. Cranedge team is of around 200+ such crane specialists possessing in depth knowledge of various material handling components for any brand or makes. The team, while rendering services to different customers, has also meticulously compiled data of over 35000+ cranes of different makes, transforming it into a large ‘Knowledge Bank’. Thus, we are equipped with all the essentials required to address any material handling related distress calls. One such distress situation is discussed below:

Distress Signal: A Case Study!

A major renewable energy sector company faced a distress situation in the year FY 2015-16. Their plant caught a sudden fire that consumed all of its inside machinery and severely damaged the over cranes as well. The company had commitments towards their customers, and they could not afford to stay sedentary for long. The customers production team was committed to restore back its full production at the very earliest. The entire team at the wind energy producing unit was determined to rebuild the facilities in the shortest possible time and immediately start production. Whatever was to be ordered under Capex, was immediately taken up.

EOT cranes play a vital role in the manufacturing process of blades and towers, as expressed in our previous blog (Wind Energy)

Operating without the cranes was an impossible task. Considering this aspect, reinstalling the cranes was among the top priorities for the company. For this, they had two options – the first was to order completely new cranes, and the second was to explore refurbishing the existing damaged cranes. Considering the condition of the damaged cranes, the client’s production team wanted to rule out the refurbishing option. While assessing the delivery period of the new cranes, they realised that it would take at least 10 weeks of time to manufacture the cranes & start installation at their site. 10 weeks was drastically long period given the tough situation. In order to meet their delivery commitments to their customers, it was imperative to start production within four to five weeks (maximum).

Thankfully, the manufacturing unit had an AMC for all their cranes with industry experts, Cranedge. Team Cranedge was at site immediately, to assess the damages. While assessing the extent of the damage to the ten cranes, they found that all the cranes were severely damaged barring the steel structure, which needed some modification & painting. Rest all the electrical, hoisting machinery, control circuits were rendered useless. They also understood the dilemma of the customer about being unproductive for long as the end clients were getting hampered.

Our Solution!

The open option for the Cranedge specialists was to refurbish and restore the damaged cranes. Was it Impossible? Not for Cranedge! An urgent meeting with all global network suppliers was called upon at the Cranedge HO and were requested to co-operate and supply the, crane kits, electricals, cables & all necessary spares at the earliest. Plans were chalked out, engineers were sanctioned at the distressed plant, schedules were set, and workforce was planned to start work at site, round the clock. The parent company, ElectroMech, stepped in to look over the situation & provide assistance wherever required. All necessary spares were despatched on war footing. The excellent coordination, perfect planning and hard work of our dedicated team yielded results on Day 15, and four cranes were made operational. The remaining six cranes were also brought to normalcy with equal diligence and speed within the next 15 days.

All the refurbished ten cranes were duly load tested, certified by authorities & handed over to for production within 30 days, as assured by team Cranedge. The production at the manufacturing unit begun operations in full swing.

The customer still has goose bumps when he remembers of the situation, but also extends a heart felt thank you to the members involved from Cranedge – Ultimately, customer satisfaction is the final goal!

A classic example of how the Cranedge team responded to a distress situation! This case deserves a special attention from all our readers, that no matter how small or big the distress signal, responding and attending to the situation is the only way forward.

If you feel, your cranes and related material handling equipment needs a ‘specialists’ eye’ to see through the odds, then we are just a call away!

Before

crane part before cleaning

After

crane part after cleaning

Before

crane part before cleaning

After

crane part after cleaning

Before