Are you investing too much, too little or too late in your crane maintenance efforts? An in-depth reliability survey can be invaluable in helping determine what level of this maintenance is optimal for your operations
It’s widely known that investing effectively in crane maintenance can help reduce the risk of safety and environmental incidents, breakdowns, loss of production and premature equipment failure. Unfortunately, what level of investment is “optimal” is not as well known.
There are various levels of crane maintenance that dictate what value, benefits and return a company
can expect on their investment. The optimal level must not only remediate risk factors but also demonstrate a measurable return on investment.
Since cranes are designed for 24/7 use, they call for maximum reliability. They must be able to answer the most stringent performance requirements, including: automation, highly demanding duty cycles, difficult operating environments, high operating speeds and special control systems.
The cost of downtime for a crane that is part of a process can easily exceed R1 million per day.
Optimal maintenance of cranes can significantly reduce overall operating costs associated with downtime, etc., while boosting productivity. This is considered a proactive maintenance approach. In order to truly develop a proactive maintenance strategy, companies must conduct an in-depth crane reliability survey to gain the insights needed to develop their plans.
Systematic and exhaustive surveys of this type will provide the facts needed to develop a smart strategy. In-depth crane reliability surveys also generate the information needed to enhance safety and mitigate issues, improve performance and reliability and extend the service life of a company’s cranes.
Types of crane survey’s to ensure your cranes safety, reliability and cost effectiveness:
1) Core inspection and analysis…
A detailed inspection is required. A field inspection should include gathering information on the overall crane condition as well as interviewing the crane operator. The crane should be inspected and the service life analyzed.
2) Structures and working conditions…
This study provides an overall analysis of the crane’s condition by evaluating the operating environment, the present state of the power supply, the alignment of the crane structure, its associated runways and the steel structures of the equipment. A series of four exhaustive analyses should be performed.
The component analysis is a specific, detailed assessment of the present condition of the crane’s electrical components — all motors, gearboxes, hook block assemblies and the wire rope and its revving component. It is important to evaluate the risks that can lead to production loss from component failure and explore options to minimize such occurrences.
Determining the condition of the crane’s hoisting and traveling gear is critical. Based on international standards, the hook and hook block should also be examined.
4) Maintenance and reliability…
During this phase, evaluate the overall maintenance of the crane by analyzing the reliability of the crane. The purpose of this analysis is to define the reliability of the crane and identify the most critical components that could cause downtime.
Next, evaluate all costs associated with the operation of the crane in a cost analysis. This analysis documents the company losses—time and monetary—as a result of inefficient equipment. Examine maintenance and operation records from a two-year span to determine the duration and frequency of a crane’s downtime and its overall impact on the production line. During this phase, analyze maintenance costs, production and quality losses.
Moreover, a complete audit of the current maintenance situation of the company’s material handling equipment is recommended. A company can obtain the Services from a Service Team which include a qualified LMI to do the survey through a LME, found on the department of labour website.
Whatever approach you take, the point is to help you determine that “optimal” level of maintenance that will keep your cranes up and running as scheduled—safely, reliably and cost-effectively.
Without disrupting your productivity, FB Cranes can conveniently send an experienced, highly qualified Lifting Machinery Inspector to your business to conduct a comprehensive 50 point Crane Health Audit.
The 60 minute Crane Health Audit comes with a detailed report and a comprehensive one on one explanation.
Our 50 point Crane Health Audit usually costs R1249, but for the next three weeks we have 19 Crane Inspections going for an unbelievable price of R625. Invest in your Crane and your Business, fill in the form below and we will conveniently call you to setup a Crane Health Audit.