Transcript Set title in verdana 34pt. bold

Guidelines for Good Clean Livin’
SC&RA webinar
Presenters: Mike Brunet, Dan Snook, Brian Hill, John Alexander,
Scott Mohn and Gary Herrmann
Roundtable topics
• Employee training and education
• Proper preventative maintenance
• Advantages of using telematics
• Overload occurrence
• Structural repairs
Employee training & education
Mike Brunet
Product safety director, Manitowoc Cranes
Getting serious about employee engagement
Were your employees engaged in 2011?
Gallops and Towers Watson results show:
• 29% are fully engaged
• 54% are partially engaged
• 17% are actively disengaged
Benefits of employee engagement
Companies with engaged employees experience:
• Less turnover
• Higher than average client retention
• Above average productivity
• Safe work environment
• Higher profitability
Employee development
• Create engaging training and development programs
• Ensure training is compelling and ongoing
• Set goals and get performance feedback
• Get company leaders on board
6
A Tale of Two Worlds
Group A: high school graduates and tech school graduates
have volunteered for rigorous positions in a variety of
marine operations.
Group B: representing the future, arrives at front door for
1st day of training/new employees, get greeted, and are
ready for grueling instructor-led training (or “death by
PowerPoint”)
7
A Tale of Two worlds, cont.
Group A: joined organization with long history of high,
short term personnel turnover
Organization A: relies on immersive training involving
gaming and virtual worlds
Group B: employed by an industry sector known for rapid
boom/bust cycles – gas and oil, construction
Organization B: relies on traditional methods
8
How long to train experts?
• One school of thought suggests experts
require 10,000 hours of work in the field:
8 hour day, 5 days/week = about 1,920 hours/yr x 5 years
• Full trained team member in 1.5 years requires increased
training by 347%
• Group A has been trained at this accelerated rate since
1775
9
Compare to traditional industrial training
• Group B training led by competent subject
matter experts
• Impart their knowledge in a
format that dates back to 1775 –
The CLASSROOM
• Classroom is still a viable tool,
but it must be augmented
10
Been There, Done That
Better to learn and make potential, catastrophic life
threatening mistakes in a classroom or simulator
Do you want workers engaged in real situations to make
near instantaneous decisions and thinking “I have never
seen this before”?
•Over the ocean at 40,000 ft., pilot says “do not worry, we
have not encountered this situation before”
•“Houston, we have a problem….”
•“I signaled Pick the load up, why is the load moving to
the left, trapping me against the wall…”
11
Been There, Done That, cont.
Imagine news media interviewing your operator, rigger,
signal person, who is cool and calm, saying, “This is just
part of my job – no big deal.”
This response is largely because of training:
Been There, Done That
12
Important assets
Big bucks and careers on the line
Refinery turnarounds, sports arenas, building the Freedom
Tower, putting the space shuttle on the aircraft carrier…
These tasks will come to screeching halt without
competent men and women necessary to:
•Assemble the equipment
•Maintain the equipment
•Operate the equipment
•Rig and move the loads
13
Legal Responsibility
Board members and top executives may have personal
culpability if discovery process exposes personnel
competency management issues.
14
Training Summary
Now, more than ever, trained, high performing
operators, riggers, signal people, technicians
are truly required for long-term success.
Two questions:
1.Why would a new hire want to
come work for your organization?
2.Without trained operators, riggers, signal
people, and technicians, what is the
future value of your organization?
15
Proper preventative maintenance
Dan Snook
Corporate training, MTU/Mercedes
Brian Hill
Field service manager, Manitowoc Crane Care
Maintenance recommendations
Why follow the manufacturer’s maintenance
recommendations?
•Decrease cost of operation
•Avoid downtime
•EPA compliance
•Record keeping
•Approval of fluids and lubricants
17
Maintenance recommendations, cont.
The following are especially important:
•Use of proper oils as recommended
•Coolant recommendations
•Air intake
•Fuel system
18
Recommended maintenance intervals
Following recommended maintenance intervals will
help maintain the safety, dependability, and
productivity designed into your crane.
•Intervals are based on average operating
conditions
•Can and may be adjusted to meet the
specific operating conditions of your crane
•Observe crane performance before adjusting
intervals
•Perform oil analysis at to refine oil-change intervals
19
Maintenance intervals
• Maintenance and inspection intervals are
based on hours of operation or calendar
based intervals.
• Daily or 8 hour inspections are typically
visual and operational inspections. Fluid
level checks may also be included.
• Daily or 8 hour inspections are critical to complete as
they could detect small issues prior to becoming a major
issue.
20
Maintenance and inspections
Required weekly, monthly and quarterly; will become more
in depth and may require more effort to complete,
however their completion is critical in maintaining a safe
and properly functioning crane.
•To ensure complete and thorough inspections,
manufacturers will commonly include checklists with crane
documentation.
•Manitowoc Cranes has newly reformatted maintenance
and inspection checklists along with Service logs to assist
Crane owners in complying with new Federal regulations.
21
Maintenance and inspections
22
SC&RA Webinar Crane Care Guidelines For Good Clean Livin'
Maintenance and inspections
23
SC&RA Webinar Crane Care Guidelines For Good Clean Livin'
Advantages of using telematics
John Alexander
CraneSTAR/Technical Communications Director,
Manitowoc Crane Care
Telematics and the crane industry
The world of crane “telematics” seems populated
with several types of fleet owners.
• In the minority are a few who are developing systems
aimed at integrating the data into business systems
for improved fleet management.
• In the majority are those who either don’t fully
understand the technology or who question its value,
cost and return on investment.
• In the middle are those who understand telematics,
but aren’t quite sure about how to best integrate the
technology into their businesses.
25
Telematics and Cranes
Data vs. Information
How much machine data will you use?
•For the 10 to 20 percent of heavy equipment asset
managers who use telematics data, working with vast
amounts of data often seems not worth the effort.
•If you talk to telematics users you might be surprised at how little information
is actually used to efficiently manager their fleet.
•“If it ain't broke, don't fix it”. In the days when machinery was simpler to
troubleshoot and fix, that philosophy worked fine. Today the more appropriate
philosophy is: “If it ain't broke, lets work to keep it that way”.
•An effective preventive maintenance program helps…and Telematics provides
your PM program with accurate machine information.
26
Telematics and Cranes
Extended Machine Life
Maintenance optimization
•A recent study concluded that the return on investment
in preventive maintenance on heavy equipment can be as
high as 500%, with the bulk of the return coming from
increasing the equipment's useful life. For a crane,
this can be significant.
•With the improved accuracy and near-real-time availability of engine hours
and system alerts, telematics enables companies to successfully fine-tune PM
service.
Asset Utilization
•Lift Reports – The availability of lift data allows the fleet manager to monitor
the correct operation of a crane to the manufacturer’s specifications. This
again assists the “informed” asset manager to allow for the extended useful
life of his equipment.
27
Overload occurrence
Scott Mohn
Mobile crane service operations director,
Manitowoc Crane Care
Overloads
Overload: Any load lifted that is beyond the rated capacity
as outlined on the crane load chart.
Why be concerned about overloads?
1. Accidents
2. Structural damage
– Gross overload (noticeable immediately)
– Minor overload (long term damage)
29
Overloads
In the event of an overload, refer to the operators manual.
• Inspection requirements for overload checks are broken
down into 3 areas of inspection, by percentage overload:
– Boom (0-25%, 26-49%)
– Super Structure (0-25%, 26-49%)
– Carrier (0-25%, 26-49%)
• These inspections are only for overloads up to 50%
overload. Anything beyond 50% requires the user to
contact the manufacturer for further instruction.
30
How to address overloads
Operator’s manual
Overload inspection
This information supplements the Load Moment Indicator (LMI) manual
supplied with each Grove crane. When the LMI system has acknowledged an
overload on your crane, you must carry out specified inspections on the crane.
These inspections apply only to overloads up to 50%. For overloads of 50% or
higher, crane operation must be stopped immediately and Crane Care must be
contacted for corrective action.
WARNING
Overload Hazard!
To avoid an accident caused by overload damage to your
crane:
*Perform the inspections outlined in this publication for
overloads up to 50%.
*Stop operating the crane and contact Crane Care
immediately for overloads of 50% and higher.
NOTE: If your crane is equipped with CraneSTAR, an overload warning will be posted to the web site for review by the
crane owner.
Overload warnings do NOT indicate real time events! Warnings could be sent 24 hours (or more) after the actual event.
31
Boom inspections
Overload less than 25%
1
Sheaves
Inspect all for damage.
2
Luffing
Mechanism/Cylinder
Inspect for damage/leaks.
3
Collar-wear pads
Inspect all for damage.
Overload from 25% to 49%
32
1
Sheaves
Inspect all for damage.
2
Luffing
Mechanism/Cylinder
Inspect for damage/leaks.
3
Collar-wear pads
Inspect all for damage.
4
Collar-welds
Inspect all for cracks.
5
Telescopic Sections
Inspect for bent or twisted sections. Check
the boom for straightness.
6
Lift Cylinder Head
Area
Inspect for bends or cracked welds.
7
Turret-Base Section
Inspect for cracked welds.
8
Locking Area (Pin
Booms)
Inspect for elongated holes.
9
Welds
Inspect for cracks.
10
Paint
Inspect for cracked paint which could
indicate twisted, stretched, or compressed
members.
Benefits of following guidelines
• Safety
• Longevity of Crane
• OSHA compliance
33
Structural repairs
Gary Herrmann
Structural engineer, Manitowoc Crane Care
Involving the manufacturer
When a repair is required, why should you request repair
instructions from the manufacturer?
•Get a Proper Repair
•Maintain Equipment Value
•OSHA Requirements
•Liability
•Product Improvement
35
Proper repair
All steels are NOT created equal.
36
Maintain equipment value
Your equipment will better maintain its value if repairs have been
done correctly in accordance with the manufacturer’s instructions.
37
SC&RA Webinar Crane Care Guidelines For Good Clean Livin'
OSHA
Requirements for load sustaining structural components in
OSHA CFR 29 Section 1926.1412(b)(1)”
•Load sustaining structural repairs must be inspected by a
qualified person
•The qualified person must determine if the repair meets the
manufacturer equipment criteria
•There are other options available, but they do not apply if
the manufacturer equipment criteria are available
38
Liability
Limit your liability!
•Follow the OSHA
requirements in
1926.1412(b) (1) (i)
•Contact the manufacturer
for repair authorization
39
Product improvement
•Sometimes the manufacturer may have already developed
a kit that can be used.
•At the very least, it gives
the manufacturer the ability
to look at repetitive or
trending repairs needed
and potential future
improvements.
40