Konecranes • More Happy Customers 1HappyCustomersAND OTHER SHORT STORIES FROM 2012
2 Konecranes • More Happy Customers Konecranes • More Happy Customers 3MissionNOT JUST LIFTING THINGS,BUT ENTIRE BUSINESSE...
4 Konecranes • More Happy Customers Konecranes • More Happy Customers 5ContentsAUTOMOTIVEAutomotive Stamping Plant...........
6 Konecranes • More Happy Customers Konecranes • More Happy Customers 7AUTOMOTIVE At our automotivestamping plant, our 75-...
8 Konecranes • More Happy Customers Konecranes • More Happy Customers 9case studycase study: crane doctorAt the Automotive...
10 Konecranes • More Happy Customers Konecranes • More Happy Customers 11case study: customer’s perspectivecase study: cus...
12 Konecranes • More Happy Customers Konecranes • More Happy Customers 13case study: VIDEOWhen a leadingmanufacturing comp...
14 Konecranes • More Happy Customers Konecranes • More Happy Customers 15case study: customer’s perspectivecase study: sal...
16 Konecranes • More Happy Customers Konecranes • More Happy Customers 17case studycase studyAt the plant...Lurking below ...
18 Konecranes • More Happy Customers Konecranes • More Happy Customers 19Hidden hazardImagine trusting your crane service ...
20 Konecranes • More Happy Customers Konecranes • More Happy Customers 21case study: customer’s perspectivecase study: cus...
22 Konecranes • More Happy Customers Konecranes • More Happy Customers 23case studycase study: customer’s perspectiveLooki...
24 Konecranes • More Happy Customers Konecranes • More Happy Customers 25case study: customer’s perspectivecase study: cus...
26 Konecranes • More Happy Customers Konecranes • More Happy Customers 27case study: salesperson’s perspectiveA difficult ...
28 Konecranes • More Happy Customers Konecranes • More Happy Customers 29case study: customer’s perspectiveMy aching backI...
30 Konecranes • More Happy Customers Konecranes • More Happy Customers 31case study: customer’s perspectiveTired of heavy ...
32 Konecranes • More Happy Customers Konecranes • More Happy Customers 33case studyCompany claimsbrake “obsolete”The overh...
34 Konecranes • More Happy Customers Konecranes • More Happy Customers 35case study: then and nowThen…The odds were agains...
36 Konecranes • More Happy Customers Konecranes • More Happy Customers 37case studymachine toolserviceKonecranes Machine T...
38 Konecranes • More Happy Customers Konecranes • More Happy Customers 39case study: QUICK FIXPETROCHEMICALHow a Simple Mo...
40 Konecranes • More Happy Customers Konecranes • More Happy Customers 41case studycase study: salesperson’s perspectiveAn...
42 Konecranes • More Happy Customers Konecranes • More Happy Customers 43powercase study: dual perspectivesHow Konecranes ...
44 Konecranes • More Happy Customers Konecranes • More Happy Customers 45case study: branch manager’s perspectiveAn unusua...
46 Konecranes • More Happy Customers Konecranes • More Happy Customers 47case studyOut of time, out of optionsAt the Los A...
48 Konecranes • More Happy Customers Konecranes • More Happy Customers 49case study: Branch manager’s perspectiveControls ...
50 Konecranes • More Happy Customers Konecranes • More Happy Customers 51case study: customer’s perspectiveSeveral months ...
52 Konecranes • More Happy Customers Konecranes • More Happy Customers 53case study: crane detectiveMysterious motor failu...
54 Konecranes • More Happy Customers Konecranes • More Happy Customers 55case studyPulp & Paper The squeaky monorailThe mo...
56 Konecranes • More Happy Customers Konecranes • More Happy Customers 57case studycase studyOut with the old, in with the...
58 Konecranes • More Happy Customers Konecranes • More Happy Customers 59case studyFrom twenty pinches to a single “bite”A...
60 Konecranes • More Happy Customers Konecranes • More Happy Customers 61case studyintermodal& RAILWorking Together to Imp...
62 Konecranes • More Happy Customers Konecranes • More Happy Customers 63case studycase study: customer’s perspectiveA maj...
64 Konecranes • More Happy Customers Konecranes • More Happy Customers 65case studysteel &primary metalsMaking Vintage Cra...
66 Konecranes • More Happy Customers Konecranes • More Happy Customers 67case study: then & nowcase study: salesperson’s p...
68 Konecranes • More Happy Customers Konecranes • More Happy Customers 69case study: customer’S perspectiveGetting Back on...
70 Konecranes • More Happy Customers Konecranes • More Happy Customers 71case study: branch manager’s perspectiveThe charg...
72 Konecranes • More Happy Customers Konecranes • More Happy Customers 73case study: customer’s perspectiveJib cranes not ...
Even More Happy Customers
Even More Happy Customers
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Even More Happy Customers

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Konecranes shares some happy customer stories from 2012, which cover many industries. From automotive stamping and assembly plants, to armor manufacturers, to offshore drilling, petrochemical, water, power and paper plants-- we cover every manufacturing industry.

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Transcript of "Even More Happy Customers"

  1. 1. Konecranes • More Happy Customers 1HappyCustomersAND OTHER SHORT STORIES FROM 2012
  2. 2. 2 Konecranes • More Happy Customers Konecranes • More Happy Customers 3MissionNOT JUST LIFTING THINGS,BUT ENTIRE BUSINESSESVision“We know in real time how millions of lifting devicesand machine tools perform. We use this knowledgearound the clock to make our customers’ operationssafer and more productive.”ValuesTrust in PeopleWe want to be known for our great people.Total Service CommitmentWe want to be known for always keepingour promises.Sustained ProfitabilityWe want to be known as a financiallysound company.Strategies> Differentiation through serviceand technology innovation> Lifting people> Global footprint and supply chain> Dual-channel> Real-time information
  3. 3. 4 Konecranes • More Happy Customers Konecranes • More Happy Customers 5ContentsAUTOMOTIVEAutomotive Stamping Plant.................. 7Automotive Stamping Plant.................. 8Assembly Factory ............................... 9Engine Assembly Plant...................... 10Automotive Facility ........................... 11GENERAL MANUFACTURINGLeading Manufacturing Company....... 13Concrete Company............................ 14Manufacturing Facility....................... 15Manufacturer of Automobile InteriorMechanisms..................................... 16K.K. Tool Company ........................... 17Toyota Lift of Minnesota.................... 18Manufacturing Facility....................... 19Piper Valve Systems.......................... 20Manufacturing Facility....................... 21Schlumberger Technology Corp.......... 22Automated Material Handling Facility.... 23Component Manufacturing Facility..... 24Manufacturing Facility....................... 25Brewery............................................ 26Chemical Plant.................................. 27Offshore DrillingComponents Manufacturer................ 28Bottling Factory................................ 29Pound Cake Factory.......................... 30Fabrication Plant............................... 31Toyota Material Handling................... 32Electrical Components Factory........... 33Christie............................................ 34Tencate Advanced Armor .................. 35MACHINE TOOL SERVICEPatterson Pump................................ 37PETROCHEMICALEngineering Company........................ 39Houston, Texas Oil Refinery............... 40Oil Refinery....................................... 41POWERLos Angeles Departmentof Water and Power........................... 43Hydroelectric Plant............................ 44Hydropower Plant.............................. 45Los Angeles Departmentof Water and Power........................... 46ACCIONA.......................................... 47Coal-Burning Power Plant................... 48Power Plant.......................................... 49Power Plant..............................................50Massachusetts Clean Energy Center’sWind Technology Testing Center......... 51ENERGY FROM WASTEEnergy-From-Waste Facility................ 53PULP & PAPERPaper Plant....................................... 55Ahlstrom.............................................. 56Southern California Paper Company... 57Paper Plant....................................... 58California Paper Mill.......................... 59INTERMODAL & RAILCSX Corporation............................... 61Railroad Yard.................................... 62Locomotive Shop.............................. 63STEEL & PRIMARY METALSAM Castle Metals................................. 65Brannon Steel.................................. 66Steel Manufacturing Plant................. 67Foundry............................................ 68Alcoa............................................... 69Metal Processing Plant...................... 70Steel Plant....................................... 71Steel Company................................. 72Manufacturing Facility....................... 73
  4. 4. 6 Konecranes • More Happy Customers Konecranes • More Happy Customers 7AUTOMOTIVE At our automotivestamping plant, our 75-ton critical crane liftsdies at full capacity inorder to meet productionneeds. One morning,our crane operatorswere hard at work whenI witnessed somethingunsettling: when thecrane attempted to makea lift, the load suddenlyand unexpectedly driftedback down to the ground.The load had only drifteddown about six inches,but we were all shaken by the event. Load drift is extremely serious and potentiallyvery dangerous. We needed to fix this issue immediately.We tried to realign the brakes, thinking we could eliminate the problem, but the loaddrift occurred on and off for six months. We called in several companies to lookat the brakes, including the original manufacturer, but no one was able to preventthe loads from slipping. During this time, the cranes experienced emergencybreakdowns at least once or twice per week. When a crane broke down, we had tocall for an emergency repair, wait for the correct parts and then perform the actualrepair. The entire process could last anywhere from four to eight hours.We needed to fix this problem immediately, so we called Konecranes. Theirtechnicians determined the factors causing the load drift: the stamping crane usedself-adjusting brakes, which were over-adjusting and pushing themselves out ofalignment. Though our cranes used variable frequency drives, they were an earlymodel. So when the brakes slipped, they did not have the technology to override themotor to prevent the load drift.Konecranes installed new variable frequency drives, which came with advancedsafety features. I like the “Brake Slip Detection” feature best: if the brake slips, theinverter drive detects it, keeps the load steady and sounds an alarm. Konecranesalso installed new, more reliable brake adjusters. We felt much safer knowing thisnew equipment minimized the potential for load drift.Now, we trust Konecranes to care for all of our cranes. They provide monthlyinspections and make sure all our cranes are running properly. Thanks to them,breakdowns at our plant have been decreased by 95% compared to last year.A Slippery SlopeA Story of Strategic Upgradescase study: customer’s perspective
  5. 5. 8 Konecranes • More Happy Customers Konecranes • More Happy Customers 9case studycase study: crane doctorAt the Automotive Stamping Plant …From the customer’s perspectiveHave you ever heard the sound of metal scrapingagainst metal? It’s a sound that will make you cringe.We heard that terrible noise at our plant as one of ourcranes traveled down the runway—the crane emitteda large, piercing shriek that startled us all. Our safetydepartment locked the crane out of service right away.We had chosen the lowest cost bidder to modify thecrane for a new runway. Well, I guess we got whatwe paid for, because when we called the companyfor help, they bluntly told us the crane was “as good as they can get it” and thatthe runway was the problem—they even suggested we grease the runway withlubrication sticks to minimize the shrieking. Of course, even with lubrication, thecrane did not track properly. To make matters worse, the crane was in the middle ofthe stamping bay, blocking the other cranes. We needed to get this crane back intoservice as quickly as possible, so we made an emergency call to Konecranes.Meanwhile, at Konecranes …From the Konecranes Branch Manager’s PerspectiveWhen Konecranes got the call, every technician hadalready been assigned to other jobs. So, I calledone of our most experienced engineers, a man wenicknamed the “Crane Doctor.” I knew he was onvacation, but I was desperate. Within two hours of theinitial call, he informed me he was leaving vacationearly to come fix the crane. Out of all the greatengineers and technicians I have worked with over theyears, I had never before seen one come off vacationto fix a crane.His initial inspection showed the crane’s internalcomponents weren’t in their correct positions, acondition that had forced the wheels out of alignment.Thanks to the “Crane Doctor,” the problem wasdiagnosed and corrected over the weekend, just intime to return the crane to service Monday morning.Back at the Stamping Plant …From the customer’s perspectiveThe crane ran smoothly and quietly down the runwayon Monday morning, and everyone breathed a collective sigh of relief. With thesafety department’s blessing, the crane was placed back into service.From Vacation to House Call“We were sothankful the ‘CraneDoctor’ was willingto give up hisvacation time tofix our crane. Heworked some longand late hours toaccommodate ourschedule, and hiscrane alignmentexpertise was veryvaluable to us.Our crane is nowrunning as goodas ever.”Stamping PlantBranch ManagerSlowed down bydaily breakdownsFrom the customer’sperspectiveIn the busiest productionarea of our assemblyfactory, a standardone-ton electric hoistloads a 1,500 poundsteel truck frame to aconveyor belt every 54seconds. This processrepeats itself constantly,as workers perform thesame action in double-shifts throughout the week. Because the crane was pickingat near capacity several times an hour, it was no surprise when the crane began tobreakdown almost daily.A customized crane built to lastFrom a Konecranes technician’s perspectiveWe found two main problems: the control system and the duty cycle. The hoistused contactor controls, which lacked high-quality speed control options andcaused intermittent damage to internal components. In addition, the crane was notdesigned to withstand the heavy duty cycles it was performing.Clearly, this standard one-ton crane was worn out and could no longer meet thedemands of the factory. So, we customized an extremely durable one-ton CXTcrane, built for severe duty, “Class E” service. The crane uses an advanced inverterdrive system, which provides smooth, controlled and precise movements. Radiocontrols allowed crane operators to control the load remotely.Keeping downtime to a minimumFrom the customer’s perspectiveWe couldn’t be happier with Konecranes’ work—and with our new crane system, weno longer have to worry about daily breakdowns.Though the sturdy new crane system was built to last, we wanted to be sure thatdowntime would not interrupt production. For that very reason, we keep an extrahoist at the facility so we can switch out the hoist any time we need to perform arepair, so that repairs can be completed quickly and accurately.Konecranes KeepsUs Trucking Along
  6. 6. 10 Konecranes • More Happy Customers Konecranes • More Happy Customers 11case study: customer’s perspectivecase study: customer’s perspectiveOld hoists –a major hindranceAt our engine assemblyplant, we rely on cranesto position enginecomponents on ourassembly line. We wereusing old air-controlledhoists which were nowobsolete. When westarted experiencingproblems, we couldn’tpurchase spare partsbecause they were nolonger available.Imagine trying to lift andassemble 300 enginesper day when your hoist isnearly impossible to use.The hoists drifted withoutwarning and were extremelydifficult to adjust. Wecouldn’t keep up with ourproduction rates with theseold hoists, so we decided toscrap them and start fresh.Konecranes improves lifting with AirBalancerKonecranes came to our facility and demonstrated their dual balancer, and weimmediately fell in love. This hoist detects when it has a part, and will remain in theair until the operator moves it. Ultimately, the AirBalancer is much easier to controland way more effective than our old hoists.Since Konecranes installed the new hoists, we haven’t had any issues withbreakdowns or unexpected load drift. Downtime at the plant has been drasticallyreduced, and we are so pleased with our new AirBalancer that we’re planning toinstall a second one!Konecranes MakesLifting a BreezeTwo of a kindIn the past several years, Konecranes and themaintenance team at our automotive facility haveworked in tandem: Konecranes performs annualmaintenance, while our in-house team inspectsour stamping cranes on a monthly basis. Whenour maintenance staff is too busy for the monthlyinspection—Konecranes handles it, using our checklist,which is based on the Ontario Green Book.We trust them completely to carry out theseinspections—we believe that whatever deficienciesKonecranes finds, our in-house team would havefound, too.The one for usInstead of relying on other crane service providers,we are depending on Konecranes more and more—eventually, they started performing inspections in ourbody shop, too. Another crane service company hadpreviously handled our inspections in the assembly linearea, but when they proved to be unreliable, we grantedthis area to Konecranes.With critical inspections from Konecranes, our plant has not had a single production-hindering breakdown in several years—clearly, we were right to trust them! Wecouldn’t be happier with the unparalleled services they provide at our facility.A dynamic duoKonecranes Helps us DrasticallyReduce Breakdowns
  7. 7. 12 Konecranes • More Happy Customers Konecranes • More Happy Customers 13case study: VIDEOWhen a leadingmanufacturing companyreleased a nationwidebid to provide cranes intheir production facility inOhio, five overhead liftingequipment companiesgave it their best shot.After reviewing theproposals, the companydecided Konecraneswas the most qualifiedto handle the entireproject—from design toinstallation.Konecranes determinedthe best equipment for the building, taking into consideration the building coderequirements, current layout and potential architectural challenges. At theproduction site, Konecranes installed three low-headroom CXT hoists with closeend hook approaches, to maximize every inch of available space in the warehouse.VIDEO: Watch a time lapse video of one of the crane installations here:http://bit.ly/CXTcraneFinding the Best FitMANUFACTURING
  8. 8. 14 Konecranes • More Happy Customers Konecranes • More Happy Customers 15case study: customer’s perspectivecase study: salesperson’s perspectiveMeet the new customerLast year, I metwith a company thatmanufactures concreteto discuss Konecranes’MAINMAN® program andthe benefits of preventivemaintenance.As we toured the facility,I asked, “How muchdid you spend on cranemaintenance last year?”“Well, between theannual inspection,several breakdowns andemergency repairs, we probably spent between $15,000-20,000,” he said. “Thosebreakdowns really slowed us down.”“You should try our preventive maintenance plan, MAINMAN®,” I said. “Theplan is specifically designed to keep your cranes in better working condition, sobreakdowns and emergency repairs won’t be as frequent.”The concrete company agreed to give MAINMAN® a try for one year, lettingKonecranes perform the quarterly and annual inspections and perform everyneeded repair.Performance reviewOne year later, the concrete company has not had a single breakdown. In fact,no production time was lost at all, because each repair was performed duringscheduled downtime.By using MAINMAN®, the company spent substantially less on maintenance. In fact,they even saved enough money to buy a brand new hoist and still remain withinbudget for the year.Leaving Downtime in the DustThe Day OSHAcame knockingIt was not a pleasant dayat our plant: we had anunexpected OSHA auditand were caught withoutproper documentationfor our overhead craneinspections. To be honest,we didn’t even know weneeded these documentsbefore the audit!In addition to the fine,now we were required tohave a follow-up audit.Needless to say, our cranes needed to be in tip-top shape (with all the rightdocumentations) before the follow-up visit.Konecranes to the rescueA colleague recommended Konecranes, a local crane service dealer, and Idecided to give them a shot. The Konecranes inspector made recommendationsbased on the specific inspections we needed. To make sure we were thoroughlyprepared for the follow-up audit, he also trained our employees on OSHArequirements for crane operators. Lastly, Konecranes repaired our cranes basedon the inspection results.Ready for the reckoningWe gave Konecranes a tight, two week deadline to make the repair. Theyunderstood the urgency of the situation and made this project a top priority, usingas many technicians as possible and rearranging welding and other schedules toaccommodate us. The repair took only one week to complete and the drum wasback in service in less than two weeks—what a relief!Inspected to Meet OSHArequirements, and beyond!
  9. 9. 16 Konecranes • More Happy Customers Konecranes • More Happy Customers 17case studycase studyAt the plant...Lurking below the surface of the gear case, glittering specks of metal rested on athick sludge of oil inside the gear case. The gear case had been neglected for yearswhile another company serviced the cranes. With damage this bad, the crane couldhave been moments away from catastrophic failure...Things were about to change: the company, which manufactured automobile interiormechanisms, released a bid for a new crane service provider, after a Konecranessalesperson explained the benefits of thorough MAINMAN® inspections.A shocking discoveryDuring the initial MAINMAN® inspection for the plant, a Konecranes inspectorpeeled open the gear case cover to find the filthy state of the oil inside. Whenhe saw glittering specks of metal, he knew that pieces of the gear teeth weredisintegrating into the oil. Quickly, he alerted the plant safety manager and lockedthe crane out of service.The plant had been extremely close to disaster. If the gears had meshed improperly,the crane could have dropped a steel die. Imagine the worst—the die plummetingfrom the crane, colliding into the machinery or workers below, smashing into otherdies and creating thick cracks on the concrete floor.Konecranes repaired the gears and explained the importance of regular gear caseinspections—the plant was extremely grateful. Now, Konecranes replaces the oiland performs open gear case inspections at the facility regularly. With MAINMAN®inspections, Konecranes hopes to help reduce the risk of close-calls like this inthe future.How a MAINMAN®Inspection Prevented anImpending CatastropheRoom to growWith customer demand on the rise, K.K. Tool neededto add several CNC machines to keep up. Themachines were squeezed into the existing shop,wherever there was room. As demand continuedto increase, it soon became clear more space wasneeded to handle the growing business.K.K. Tool expanded their facility—adding a 4,000 footaddition for the eight new machines. The company alsobegan exploring lifting options to streamline workflowaround the CNC machines.Konecranes’ space-saving craneAfter consulting with several companies, K.K. Toolcontacted Konecranes, who proposed a uniquesolution—an XN trolley and hoist on a light-trackenclosed rail system. Suspended from the ceiling, onecrane could service all eight milling machines, whilekeeping the floor area free for forklifts to maneuver.Konecranes XN crane has a distinct feature – an articulated bridge which allowsone end to move ahead of or behind the other, by as much as three feet. Thisergonomic feature significantly reduces the amount of effort needed to move thecrane along the track and allows small adjustments to be made without movingthe entire bridge.K.K. Tool has been using the XN system for about six months now, and is seeingthe productivity benefits. Due to the success of this crane system, the company isexploring the possibility of adding another XN hoist to the existing track.Right on TrackA Successful Systemto Improve ProductivityCompany Information: K.K. Tool Company is a family-owned enterprise inSpringfield, Ohio. Competing globally, the company creates stamping dies forthe heavy equipment industry and production machining products.“The only way we can compete effectively is to work withmachinery that helps us to make a product faster. So, we haveto work smart by investing not only in employees and training,but also by investing in equipment that allows us to produceproducts in a more timely manner.” ”Kris KoehlerK.K. Tool
  10. 10. 18 Konecranes • More Happy Customers Konecranes • More Happy Customers 19Hidden hazardImagine trusting your crane service provider to inspectyour overhead lifting equipment—only to find out theywere not telling you about comprehensive inspectionsthat could be critical to the safety of your personnel.That is what happened to Toyota-Lift of Minnesota,who used another crane service provider for nearly 15years without being informed of the safety benefitsinvolved with performing inspections on internalcomponents. “We had not been told about theseinspections, despite 14 annual inspections performedby companies other than Konecranes,” said Kyle Thill,Director of Service at Toyota-Lift of Minnesota.The standard inspections performed at Toyota-Lift ofMinnesota relied mostly on visual observations andmeasurements. However, not all defects can be seenwith the naked eye.Toyota-Lift found Konecranes after a few failedattempts to contact their vendor to schedule aninspection. “Their failure to do so for approximately twoweeks made us look for alternative solutions, and wediscovered Konecranes,” said Thill.Critical InspectionKonecranes worked with Toyota-Lift to develop a customized inspection plan forthe 5-ton bridge crane. Based on the equipment’s use, environment and age of thehoist, Konecranes advised Toyota-Lift to perform internal inspections on the gearcase, load block and hoist coupling.The inspections revealed that the needle bearing in the gear case had started tofail. Without this inspection, the tear could have led to a sudden and catastrophicfailure. Konecranes is now Toyota-Lift of Minnesota’s preferred vendor for craneinspections and maintenance.case study: customer’s perspectivecase studyKonecranes reduces riskwith gear case inspectionCompany Information: Established in 1978, Toyota Lift of Minnesota currentlyoffers a full line of high-quality lift trucks, aerial equipment, personnel and burdencarriers as well as warehouse and material handling systems.“Now we have the comfort of knowing this piece of equipment isoperating safely.”Kyle ThillDirector of ServiceNew facility needsa brand new craneLast December, ourcompany needed a one-ton workstation crane forthe new facility we werebuilding. The project wascomplex for a numberof reasons: our facilityutilized boilers for heattreating, which requiredpiping on the walls. So,the workstation neededto work around thepipes. Our building wasnearly finished, so weneeded to get a quote assoon as possible.Konecranes proves to be the right choiceWe gathered quotes from several crane companies, but we still weren’t satisfied.That’s when our production supervisor suggested that we call Konecranes, sincethey had been performing our overhead crane inspections for the past three years.They prepared a quote for the project in just one day and proved to be the mostcost-effective option when we considered total cost of ownership.Konecranes delivered the one-ton XM workstation with two half-ton bridges in justthree weeks. With the chain pendants and the push/pull bridges and trolleys, wecan move products in and out of our heat treatment system with ease. Betteryet, this freestanding system doesn’t interfere with the piping. Overall, this newprocess is much faster, and the lightweight crane proves to be much easieron the workers.New Building? New Crane?No Problem!
  11. 11. 20 Konecranes • More Happy Customers Konecranes • More Happy Customers 21case study: customer’s perspectivecase study: customer’s perspectiveMAINMAN® catchesmajor problemWhen we first triedKonecranes MAINMAN®inspections, we noticed avast difference. Insteadof a simple checklist for“Compliant” or “Non-Compliant” items, theMAINMAN inspectioninvolved details, graphsand a plan of action. Notonly that, the inspectionsincluded components ourchecklists missed – namely, our trolley gauges, which needed to be re-adjusted. Weare glad these problems were spotted so the proper adjustments could be made:this damage could have led to derailment, skewing or a load drop.Reaching far beyond inspectionsAfter Konecranes solved this problem for us, we had another major need in ourvalve-testing area. We had only one jib to cover two bays. Our forklift trucks wouldattempt to attach the valves to the jib, but the grated floors prevented the trucksfrom moving all the way into the testing space. Then, our workers needed to scootthe valves the rest of the way with manual push pallets. Clearly, this situation wasnot efficient or safe.Thankfully, Konecranes custom-built a solution: Workstation Lifting System jibcranes with a bridge in between them. Because this system was mounted directly tothe wall, it did not require any floor space and spanned much more floor space thanan additional jib could have. Now, our XN chain hoist can travel through the entiretesting area, which lets us transport valves twice as fast as our original situation.Thanks to Konecranes, our plant is well-maintained and running smoothly!Konecranes Gives our Planta Much-Needed MakeoverCompany Information: Piper Valve Systems produces compact high pressure valvesand manifold system components for the oil and gas industry.Limited mobility leadsto limited productivityAt our facility, we relyon our overhead cranesto lift molds into aplastic injection moldingmachine. Our originalsystem was outdatedand not very productive:the machine wasmisaligned and couldn’tmove left to right.This meant that ouremployees had to pushthe crane by hand, andforce the molds into place. Not only was this extremely difficult, but it also slowedthings down significantly at the plant. On top of that, the cranes used pendantcontrols. Since the cords were not very long, employees often had to stand on themachine to operate it.It was time for a change—we needed a new system that would eliminate thesemobility issues and increase our efficiency.Konecranes sets plant in motion with new crane systemKonecranes had the perfect solution: two 175’ long, two-ton capacity freestandingworkstation cranes with radio controls. Now, we no longer have to worry aboutpushing the cranes by hand. Instead, the new workstation cranes lift and load ourmolds with speed and precision. The radio controls allow our operators to maintaina comfortable distance from the cranes, since they are no longer limited by cords.Overall, we’re very pleased with our new cranes. Konecranes technicians were ableto install the new system without interrupting production. Now, we feel confidentthat our plant can run efficiently!Konecranes Keeps us Movingwith Workstation Cranes
  12. 12. 22 Konecranes • More Happy Customers Konecranes • More Happy Customers 23case studycase study: customer’s perspectiveLooking for abrand-new craneAt our new facility inHorsehead, N.Y., weneeded a crane as soonas possible to aid usin routine maintenanceof our Coil TubingServices truck and trailerfleet. This crane alsoneeded to be capableof lifting the devices weproduce—some of whichcan weigh up to 4,000pounds. Because ourbusiness is constantly growing and expanding, we needed to find a crane companywho could not only provide us with reliable equipment, but also with fast, excellentservice.Konecranes proves to be the perfect fitLeChase Construction Services recommended that we call Konecranes—they hadpurchased cranes from Konecranes in the past and assured us they were reliable.After careful consideration, we decided to go with Konecranes for five of the sixoverhead cranes in our facility.Konecranes installed a 5-ton single girder top-running crane for us. With inverters onthe bridge and trolley, our cranes run smoothly. The two-speed hoists with remotecontrols give us the control we need to operate the crane and lift with ease. We wereimpressed with their outstanding service and fast follow-up. In fact, now Konecranesis servicing all of the cranes in our plant. Clearly, we made the right choice.The Perfect Combinationof Equipment and ServiceCompany Information: Schlumberger Technology Corporation is the world’s leadingoilfield services company supplying technology, information solutions and integratedproject management that optimize reservoir performance for customers working inthe oil and gas industry.Before…Back in the day, anautomated materialhandling facility used two12-foot jib cranes in itsmanufacturing process–producing componentsfor conveyor systems.With the long, 12-foot jibcranes in the middle ofthe runway, it becamedifficult to load andunload their product.After…Konecranes replaced both jib cranes with two overhead cranes—one on a 50’runway and one on a 100’ runway system. Now, they have the entire floor spaceto load and unload their product.Going the Distance
  13. 13. 24 Konecranes • More Happy Customers Konecranes • More Happy Customers 25case study: customer’s perspectivecase study: customer’s perspectiveAn inefficient systemAt our componentmanufacturing facility,we were in the midstof putting in a newprocess, a hand peeningbooth, where workerscould chip away at themetal surfaces of the400-pound tractor-traileraxles we manufacture.We had a small handfulof employees workingon this process, whichinvolved moving theaxles using a combination of manual labor, forklift trucks and an overhead cranewith a chain host.We needed a new crane system that would allow us to lift and place the axles faster.Konecranes sets plant in motion with new crane systemKonecranes installed two free-standing XM Workstation cranes in order to eliminatethe issues we were having. About halfway through the installation, the Konecranesteam and I came to the realization that this system wasn’t going to work for us.We had hired more employees, so we needed more workstations for them touse. Konecranes immediately began to help us re-strategize: in order to be moreproductive, we needed to be able to have more employees lifting and working on theaxles at one time. Konecranes suggested that we add more bridges, which wouldgive us more flexibility and add additional workstations for our employees to use.The perfect fixRather than having us purchase an entirely new system, Konecranes engineersused all the existing components of the XM Workstation cranes to develop anentirely new system, which saved us a good bit of money. Now, instead of threebridge workstations, we have 10, and we couldn’t be happier with our new system!Konecranes Redesigns CraneSystem to Suit our NeedsTime for a changeWhen our original craneservice provider wasacquired by Konecranesseveral years ago, wewere required to changeour maintenance plan.Konecranes worked withus extensively to ensurethat our transition wentas smoothly as possible,especially since we werealready accustomed toour regular maintenanceplan. As we worked withKonecranes on a new contract, they took extra care to make sure their employeeswere well-equipped to take care of our facility—each employee underwent specializedtraining so they would know our safety policies and operating procedures.Konecranes MAINMAN proves to be the bestI was a little reluctant to try Konecranes’ MAINMAN inspection program, especiallysince I had been satisfied with our previous inspection contract. As soon as westarted working with Konecranes, I immediately fell in love — I was impressedby how convenient it was to plan repairs in advance and check the progress ofinspections and repairs online!Konecranes continues to work closely with us to make sure all our equipment iskept in top condition. We were so impressed with Konecranes’ ability to handle ourinspections that we started to trust them with larger projects as well — now, they’reworking on two full-scale engineering jobs at our refinery.Making the Switch:Konecranes Eases theTransition to MAINMAN®
  14. 14. 26 Konecranes • More Happy Customers Konecranes • More Happy Customers 27case study: salesperson’s perspectiveA difficult missionA chemical plant located in Texas needed to increase the stability of their cranes byupgrading to inverter drives. The air-controlled cranes regularly performed high liftsat nearly full capacity. The heavy duty cycle, combined with the hot environment ofTexas, caused the mechanical load brake to overheat frequently.Inverter drives would eliminate the need for a mechanical load brake and wouldease the plant’s problems. There was just one catch—due to the high levelsof chemicals in the plant, the new control system would need to be specificallyengineered to withstand explosive environments.Konecranes engineers face the challenge head-onWhile other competitors shied away from the project, Konecranes had both theresources and the expertise to develop a system to allow inverters to run in thehighly-reactive environment.With top-of-the-line equipment, Konecranes engineered explosion-proof panelsdesigned to prevent chemicals from entering the control box. For added protection,the engineers developed a system to pump a constant flow of pressurized air intothe control box. The pressurized air was also designed to protect the controlsfrom heat damage. Now, the plant can reap the benefits of inverter drives in anenvironment where the drives normally could not exist.Mission: Impossible?Konecranes PerformsAdvanced Modernizationin Hazardous Environmentcase studyMonthly breakdownsreveal the needfor a more proactivemaintenance planA brewery in Ohio utilizeshundreds of overheadlifting equipmentthroughout their facility.Their crane maintenanceteam performedregular inspections asrequired, but did notproactively seek toreduce breakdowns. In aparticularly high volumearea, a few of the cranes regularly broke down on a monthly basis.They needed to find a way to reduce these monthly breakdowns in order to increaseproductivity.Working to prolong crane lifeKonecranes performed an in-depth inspection on each crane, searching for defectsand deficiencies. Experienced technicians followed the Konecranes MAINMAN®process, evaluating the condition of every crane in the building and ranking thecranes based on safety and production needs. A customized maintenance plan wascreated based on the condition of the equipment and the production needs.The brewery made each repair in a timely manner, with hopes to reduce downtimedue to breakdowns. Technicians replaced brake pads, which had been wearing thin.Without the thorough brake inspection, the worn brakes could have led to a loadfailure. Any chain hoists with defects, rust or corrosion were replaced with newKonecranes XN hoists.With every item thoroughly inspected and repaired, breakdowns and repair costshave been drastically reduced.Proactive Care ReducesBreakdowns by 99%
  15. 15. 28 Konecranes • More Happy Customers Konecranes • More Happy Customers 29case study: customer’s perspectiveMy aching backI’ve been working at a bottling factory inColumbus, Ohio, for years. As bottles spinacross the conveyor belt, a machine wrapsthe labels around them. In the past, whenthe labels needed to be replaced, we hadto lift a 75 pound block of labels and feedit into the machine. I left work every dayfeeling exhausted and sore. I started todread having to lift those labels becauseit strained my back so much. I knew otheremployees felt the same way, so I finallydecided to take action.A better way to lift labelsThe factory manager agreed when I told himthat something needed to be done, so hecalled Konecranes and started discussingsome possibilities. After reviewing a lot ofdifferent lifting devices, he decided that an XM freestanding aluminum system with anAirBalancer hoist was the best choice. Konecranes installed the entire crane systemin only two days, and I couldn’t wait to start using it.Konecranes AirBalancer provides much needed reliefThe AirBalancer is great for so many reasons— first, the custom-built runway coversthe length of all three of our labeling stations, so everyone can use the hoist.Second, the AirBalancer instantly senses and counteracts the weight of the labelblocks, so the load feels practically weightless to me! And then, with just a flip of aswitch, the air hoist turns into a manipulator, so I can move and place the labelingblocks without straining my back. So now, lifting those labels is no problem!AirBalancer’s Got My Backcase studyKonecranes providescomprehensive,hands-on trainingThe Konecranes TrainingInstitute’s relationshipwith this offshore drillingcomponents manufacturerbegan in 2008. Several oftheir facilities throughoutthe country have receivedon-site, Train-the-Trainerinstruction from theInstitute. Crane operatorswith varying levels ofexperience, from asfew as two years to asmany as 25, have participated in the training program. Instructors of the Instituteput knowledge in layman’s terms and perform hands-on training to show employeesproper rigging techniques, load ratings and inspections on their equipment.The training continuesToday, the training relationship continues toevolve and now includes training for Rigging,Mobile Crane Operator and Hand Signal Training.Konecranes provided eight courses for them in2011 and continues to offer classes in 2012.Jim Lang, General Manager for the KonecranesTraining Institute said, “In 2011, we trained over80 of their personnel in our customized Train-the-Trainer program.”Enhancing Safety withCrane Operator Training“Even employees withmore than 15 years’experience said theycame away from thecourse having learnedsomething new.”Regional Manager
  16. 16. 30 Konecranes • More Happy Customers Konecranes • More Happy Customers 31case study: customer’s perspectiveTired of heavy liftingAt our plant, we needed a new crane to help usperform machining and tooling tasks and loadproducts into fabrication machines. We received anew machine tool, and desperately needed a newcrane for that workstation area.Light as airWhen Konecranes came to demonstrate AirBalancer,an air-controlled hoist and manipulator on anextremely lightweight, freestanding aluminum system,we all immediately fell in love with it. The hoist madeitems feel practically weightless!Konecranes installed a 500-pound capacity aluminumXA crane with a 100-pound capacity AirBalancerin only a few days. The freestanding crane systemimproved our whole situation in general. Becauseit spans the entire workstation area, we are able tomove the hoist exactly where we need it. We caneven add more units as we grow. With AirBalancer,employees can perform all machining and toolingtasks with ease.AirBalancer AllowsEmployees to Lift with Easecase study: customer’s perspectiveThen...At our pound cake factory, we were stuck withan obsolete, out-of-date overhead crane. Thecrane was crucial because it was used to performmaintenance on our conveyor belt. But becausethe crane was so old, we were constantly dealingwith breakdowns and the crane needed to berepaired frequently. Whenever the crane brokedown, we lost hours of production time.Several of our other facilities were usingKonecranes hoists, and were very enthusiasticabout these cranes. So, we decided to follow suit.Now...After touring our facility, Konecranes recommendeda 1-ton capacity XN hoist, with a food-grade hoistso it would not contaminate the product. As soonas they installed our new crane, we were impressed!Now, Konecranes provides yearly inspections and preventive maintenance to ensurethat the new crane doesn’t break down. With fewer breakdowns, we can focus onour pound cake instead of worrying about expensive emergency repairs!With Konecranes, ReducingBreakdowns is a Piece of Cake
  17. 17. 32 Konecranes • More Happy Customers Konecranes • More Happy Customers 33case studyCompany claimsbrake “obsolete”The overhead crane atan electrical componentsfactory broke down aftera bridge brake failed. Thecrane was an essentialpart of the manufacturingprocess, as workersused it to transportsteel to fabricationmachines. When thefacility asked theircrane service provider to replace the part, the service provider claimed the partwas obsolete. There seemed to be only two options: replace the crane entirely orcustom manufacture a new part. Both options would be expensive and could requiremonths of downtime.Konecranes finds correct partThe facility contacted Konecranes for a second opinion before moving forwardwith a new crane. Konecranes assured them the problem could be easily solved,and the part needed was not actually obsolete. Konecranes technicians gatheredinformation from the brake plates and used this information to determine thecorrect brake style for the crane.Part ordered and installed in two weeksKonecranes technicians set the brake according to OEM requirements. After performingan operational test, the crane was placed back into service—only two weeks after thebreakdown. With the quick brake installation, Konecranes saved the facility thousandsof dollars in remanufactured parts and weeks of unnecessary downtime.Quick Thinking Saves CustomerWeeks of Downtimecase studyThe Konecranes SMV lift truckknocks out the competitionBetter, faster, stronger:Lift trucksCompany Information: Toyota Material Handling is Northern California’s leading fullservice Material Handling dealer of everything from lift trucks to utility vehicles.It was time for us at Toyota Material Handling NorthernCalifornia to make a tough decision: Which lift truck shouldwe choose for our customers? We had three rounds todecide, based on Maintenance, Strength and Cost.Stepping into the ring, the SMV Konecranes lift truck showstremendous reliability, with a load sensing hydraulic systemthat only needs to be serviced every 4,000 hours. What atough number to beat!Here comes the rest of the competition, with service required every 1-2,000 hours.The First Round goes to … Konecranes SMVBut lift trucks need more than just low maintenance costs; they need to be tough.Which lift truck is stronger, tougher and more durable than the rest?In a test of strength, the Konecranes SMV is the clear winner. On average,Konecranes’ box section frame is twice as strong as the channel “C” frame thecompetition uses.The Second Round goes to … Konecranes SMVThe crowd is anxious for the final, and possibly most important, round. Which truckis the most cost-effective? Knocking out the competition, the Konecranes Lift Truckshows off an astonishingly reasonable price tag!And the Winner is … Konecranes SMV!“At Toyota Material Handling of Northern California, we know achampion product when we see one. That’s why we chose tosupply the Konecranes SMV Lift Truck to our customers.”
  18. 18. 34 Konecranes • More Happy Customers Konecranes • More Happy Customers 35case study: then and nowThen…The odds were against Tencate AdvancedArmor. They desperately wanted to bidon a multi-million dollar order to createbulletproof lining for vehicles, and they hadan extremely short time frame to provethemselves. Relying on forklift trucks,they were only producing 50 armoredlinings per day—a mere third of what thenew order required. If they were going towin this order, they needed to triple theirproduction rate, and they needed to do itimmediately.With time running out and the oddsstacked against them, Tencate calledKonecranes. Working as quickly as theycould, Konecranes determined severaloptions. Given the time constraints, itwould be impossible to install overheadcranes—that would take weeks. There hadto be another solution…That’s when it hit them: freestanding XM cranes with vacuum lifter attachments.They were installed in a matter of days—no time was wasted. Four days later,Tencate had a brand new system that allowed them to change the aluminum dieswith speed and precision.Now…So, did their plan work? Were they able to succeed? Yes! Because the upgradewas completed so quickly, Tencate won the order by proving that they had what ittook to meet the production requirements. Now, they produce a record-breaking200 aluminum molds in one day—above and beyond any amount they could haveproduced when they were using their forklift trucks.Hitting the TargetKonecranes Helps Tencate WinMulti-Million Dollar BidCompany Information: Tencate Advanced Armor manufactures armor lining forNorth American military vehicles. The bullet-proof armor fabric protects militaryvehicles from bullets, fire and improvised explosive devices (IEDs).Wanted: sleek,top-of-the-line cranesChristie was building anew showroom for its high-end projector systems soclients could preview theirinstallations. They needednew cranes that couldassemble their rear-viewprojectors with precisionand care, especiallysince these componentscould cost up to a milliondollars. Christie not onlywanted a reliable system, but also wanted cranes that would be visually compatiblewith their sleek, modern equipment.Konecranes installs brand new XN systemKonecranes provided exactly what Christie needed: a brand new XN enclosed tracksystem. This system suited Christie’s needs for a number of reasons: first, the twoworkstation cranes were highly ergonomic, with variable speed drives for bridge andtrolley motions. Second, the cranes were capable of supporting centers up to 30 feetalong the runway, which reduced the need for additional support. Third, the systemwas easy to operate and moved with precision. Finally, the entire system had a clean,uncluttered look, so aesthetically, it was an easy fit into Christie’s showroom.Reliable cranes a big hitOverall, Christie was pleased with their new installation. Luis Laino, manufacturingengineer at Christie’s showroom said, “I can lift a $50,000 component, and if itfalls, it will fall all over a project that someone has paid up to a million dollars for.[These cranes] are reliable—that is my favorite feature! Over the last year and half,absolutely nothing has happened to them or the loads they’ve handled.”More than just a pretty craneReliability and PrecisionProtect Christie’s ProjectorsCompany Information: Christie is a global visual technologies company offeringsolutions for business, and entertainment. Audiences have been awestruck bytheir over-the-top projected virtual reality events at venues such as the 2010Vancouver Olympics.case study
  19. 19. 36 Konecranes • More Happy Customers Konecranes • More Happy Customers 37case studymachine toolserviceKonecranes Machine ToolService Provides Decadesof Excellent ServiceA facility filled withcritical machine toolsPatterson Pump, a manufacturerof some of the world’s largestwater pumps, relies primarily onlarge sophisticated machine toolsto manufacture a variety of theirproducts. These machine toolsare in production 24/7 and arethe lifeline of their business. Withmachine tool downtime potentiallycosting the plant anywherebetween $200-600 an hour, it isessential these machine tools arekept in excellent condition.Machine Tool Service keeps facility running in peak conditionThe experts at Konecranes Machine Tool Service have been supporting PattersonPump for over 20 years – prior to October 2009 operating as Machine ToolSolutions Unlimited. As Konecranes Machine Tool Service, they continue to providethe same quality rebuilding, retrofitting and preventive maintenance services today.When a flash flood left every machine tool in their facility damaged, Patterson Pumpcontacted Konecranes Machine Tool Service to handle the recovery process. Underthe direction of Harold Schoch, Machine Tool Services Director of Sales, numerousMachine Tool Service specialists were deployed, along with several Konecranescrane specialists, to support the recovery.Working in concert with Patterson Pump employees, Konecranes machine tooland crane specialists repaired all of the machine tools and placed them back intooperation in a timely and efficient manner. This prompt workmanship resulted insubstantial savings to Patterson Pump.Beyond Machine ToolsPatterson Pump was recently looking to purchase two 75-ton overhead bridge cranes.Due to the excellent service Konecranes Machine Tool Services provided to thefacility, Patterson Pump decided to purchase this new equipment from Konecranes.Company Information: Patterson Pump is a world leader in fire protection andmunicipal pumps, using the latest in computer aided pump design to offercustomers state-of-the-art products.
  20. 20. 38 Konecranes • More Happy Customers Konecranes • More Happy Customers 39case study: QUICK FIXPETROCHEMICALHow a Simple ModernizationAdded Multiple ProductionHours to the DayJust out of reachOur engineering company used to deliver tanks fromthe paint shop directly to the loading dock. When wechanged our manufacturing process and stoppedpainting these tanks, we had to change the locationof our loading dock. This change should have beenseamless, yet it turned out to be a major problem. Ouroverhead crane had a limitation setting built to suitour prior needs. This feature forced the crane to stopat a certain location along the runway—which nowhappened to be a few feet short of the loading dock.We tried to override this setting to allow the crane totravel the last part of the runway to the loading dock,but with the crane’s limited control system, it simplywas not possible.For nearly four months, we compensated–using lift trucks to carry the load the last fourfeet. This maxed out the lift trucks and wasted valuable time; after lowering the loadfrom the crane, the rigging was removed and then the load was strapped to the lifttrucks for the remainder of the journey. The system also presented a potential safetyhazard. As manual labor increased, injury potential also increased.Konecranes’ quick fixFor many years, we had been dissatisfied with our crane service provider, which iswhy we decided to contact Konecranes.Konecranes modernization engineers quickly relocated the travel zone limit to givethe crane access to the newly-required loading area. This modernization saved 10minutes per load. With an average of 20 loads per day, this quick fix added overthree hours to our production day!Picture this: An overhead crane lifts an oil refinery tank, and it floats through thefactory like a massive white cylinder in the air. It’s quite a sight to see—that is,until the crane abruptly stops along the runway—just four feet before reaching theloading dock.
  21. 21. 40 Konecranes • More Happy Customers Konecranes • More Happy Customers 41case studycase study: salesperson’s perspectiveAn oil refinery outside ofHouston, Texas has over600 pieces of equipment,all of which need to beinspected monthly. I sendin my best, most qualifiedtechnicians to work on-site to help keep the plant100% OSHA compliant.With thorough inspectionscompleted every month,the repairs are doneas quickly as possible.However, our relationshipextends far beyondthese detailed monthlyinspections.Sometimes the refineryasks us for help with morespecialized projects. Forexample, when hurricanewinds were coming, theywere worried they did nothave a great way to lockdown their equipment. So,we helped design windlocks for them. Thesewind anchors, which are designed to lock outdoor cranes into place during severeweather, helped the refinery keep their equipment safe during the harsh storm.We’ve been working with this refinery since 1995, and it’s clear that our relationshiphas been built to last.More than JustFair Weather FriendsCracked drum requiresimmediate attentionWhen employees at thisoil refinery spotted crackson the drum of theirheavy duty coker crane,they knew they neededto act quickly. Resultscould be tragic. If thecrane was out of servicetoo long and unable toproduce petroleum for anextended period of time,the entire refinery couldbe forced to shut down.Konecranes sent an experienced modernization engineer to assess the situation.Using his years of experience, he worked quickly to diagnose the drum. He soondetermined a failure had occurred between the gear and the drum. Because theshaft was hollow, it did not provide the stability required for the crane—there wastoo much pressure on the shaft as it entered the drum.Modernization to save the drumThe engineer made the necessary repairs at Crane Pro Parts, Konecranes’ partsorganization. With great precision and care, he increased the diameter inside thehoist drum and redesigned the shaft – making it completely solid. The redesignedshaft had the necessary strength to prolong the life of this coker crane.Konecranes Enhances the Lifeof a Critical Coker Crane
  22. 22. 42 Konecranes • More Happy Customers Konecranes • More Happy Customers 43powercase study: dual perspectivesHow Konecranes helped keepthe Los Angeles City Lights OnCompany Information: The Los Angeles Department of Water and Power providesreliable electric service and safe, affordable water to the city’s 3.8 million residentsand businesses.The power for the city of LosAngeles comes from a mostunusual, yet scenic location.The Castaic Power Plantis cut into the mountainssurrounding the Castaic Lake.The plant passes water fromlocal reservoirs in order togenerate hydroelectric powerfor the city.A minuscule window of opportunityWritten from the Customer’s PerspectiveLast spring, our generator was scheduled for a complete overhaul in only a fewmonths, but we had a major problem. When our generator needs maintenance,two massive bridge cranes work in tandem to lift and carry it over 500 feet ofrailway. With the city of Los Angeles depending on the generator for a portion oftheir power supply, our window of opportunity for repairs is very small. However,our cranes were not ready to lift the generator. The rails were outside of tolerancerequirements, which had caused excessive wheel wear.Our goal was to replace all 500 feet of railway, along with 32 bogey end truckwheels in two months—otherwise, we were going to miss the deadline for upgradingour generator.Meticulous planning pays offWritten from the Konecranes On-Site Manager’s PerspectiveMy priority was to make sure this wheel assembly and rail replacement was carriedout safely and efficiently. Each day, I sat down with the branch and went over theplan for that day, working to avoid potential safety issues. Everything needed tobe scheduled to the last detail because this was a logistically difficult project. Wedevised a system to work on the railway and the wheels simultaneously. Becausethe wheels had to be driven two hours to a Konecranes service branch in order tobe repaired, we even took traffic time into consideration to make sure everythingwent smoothly.Ahead of schedule, breathing a sigh of reliefWritten from the Customer’s PerspectiveThanks to Konecranes’ efficient work schedule, the replacements were completedtwo full weeks ahead of schedule. I was so pleased with their extensive planning,hard work and dedication to the project. Konecranes went above and beyond toensure we would be able to upgrade our generator.
  23. 23. 44 Konecranes • More Happy Customers Konecranes • More Happy Customers 45case study: branch manager’s perspectiveAn unusual requestOne day, to our surprise,a competitor called ourlocal office requestingour technician’s help. Ahydroelectric plant wasexperiencing load brakeissues with one of theircranes. The plant neededto repair the crane intime for a scheduledturbine change. By thetime the competitorcalled us, the crane hadbeen out of commissionfor several days, and theywere unsure of how tosolve the problem.Speedy repair leads to new relationshipThough this was an unusual situation, Konecranes decided to step in and help.Our modernization representative worked in conjunction with two of our mostexperienced technicians to repair the crane. In just a couple of days, the crane wasup and running—just in time for the turbine change.After our repair, the plant was no longer interested in working with our competitor.Because many of their cranes are decades old, we started to work with the facility toupgrade the cranes. They awarded Konecranes with an annual MAINMAN® Inspectioncontract not only with that specific plant, but with all six plants in the area.Konecranes ComesThrough in a Bindcase study: Branch manager’s perspectiveWorn down componentspose problemsDuring a KonecranesMAINMAN® inspectionof a hydropower plant’s80-ton Turbine Roomcrane, we came acrossa major problem:the upper and lowersheave blocks showedexcessive wear, whichcould, if left unattended,lead to a breakdown.Though the crane wasused infrequently, itwas essential to the facility, as they used it to lift their enormous turbines. With ascheduled turbine replacement on the horizon for AEP, this crane needed to be intop condition. After speaking with one of our modernization engineers, we advisedAEP that they replace the sheaves in the upper sheave nest and lower blockassembly, and upgrade from bronze brushing to a newer, roller bearing for the newsheaves. They asked us to do the upgrades because of our expertise, as well asour willingness to adapt to their safety regulations.An essential repairDuring the inspection, we also discovered a second problem. The festoon hadbeen installed in the wrong location by another crane company during a previousrepair. We quickly adapted the scope of the project to include moving this festooninto the proper place. The turbine room crane was repaired and returned to serviceimmediately following the work. Even with the last minute festoon relocation, wewere able to complete the project in time for their scheduled turbine replacement.Since the repair, the crane has been performing in top condition. In the future,our goal is to help the plant reduce the need for extreme and costly repairs byimplementing a preventive maintenance plan.Konecranes Demonstrates theImportance of Proactive Care
  24. 24. 46 Konecranes • More Happy Customers Konecranes • More Happy Customers 47case studyOut of time, out of optionsAt the Los Angeles Department of Water and Power (LADWP), two massive 375-ton cranes lie in wait. Though used infrequently, the two overhead lifting devicesare essential. Working in tandem, the plant depends on these cranes to lift hydroturbines out of the building for scheduled maintenance.LADWP had a small window of opportunity to perform maintenance work on theturbines, and the wheels had worn too thin to safely perform the lift.Working together for faster speedLADWP began searching for a provider to keep the maintenance work on schedule.Konecranes won the competitive bid to design, manufacture and install wheels. Tomeet the deadline, Konecranes depended on the strong partnership between itsservice and parts departments.To determine the specific needs of LADWP, a product manager from Konecranesparts department, Crane Pro Parts, and the local service branch traveled to LADWP’ssite. While at the site, Konecranes analyzed the equipment, took preliminarymeasurements and discussed the customer’s expectations. The Crane Pro Partsproduct manager also made recommendations to upgrade the raw materialspecifications, test certification and performance requirements and simultaneouslyreplace the axles to prevent damage during removal and/or installation.The Konecranes parts manufacturing facility pushed the project forward quickly,delivering the two sets of 16 wheel assemblies ahead of schedule. The Konecranesservice team replaced all 32 wheel assemblies, allowing LADWP to complete thescheduled maintenance on time.Konecranes service and parts departments were able to partner together to helpthe end user:• Understand the scope of the challenge• Recommend a solution• Deliver the recommended solution – ahead of scheduleBy partnering together, the two departments were able to demonstrate the overallcapabilities of Konecranes.No Time? No Problem!Crane Pro Parts DeliversWheels in a FlashCompany Information: The Los Angeles Department of Water and Power providesreliable electric service and safe, affordable water to the city’s 3.8 million residentsand businesses.case study: customer’s perspectiveAn impressive featThe moment of truthhad arrived: 75 invitedguests—includingbusiness partners,elected officials andeconomic developmentleaders — stoodalongside our 100employees inside ourmassive assembly plant.As the crane lifted thecover onto the windturbine, the audienceapplauded enthusiastically. This was a remarkable achievement for Acciona andanother major step toward renewable energy solutions.The right crane for the jobAt our brand new facility in Iowa, we needed a crane that could perform a veryspecific, extremely important task. We needed a crane that could, when thetime was right, lift the 3,000-pound cover off our 130-ton wind turbine and thentransport the turbines out of the facility for delivery. This AW3000 wind turbine, anew, more powerful and efficient wind turbine, was the first of its kind to be builtin North America. We needed a reliable crane to do the job. That’s why we choseKonecranes to provide a 190-ton overhead crane for our plant.Without Konecranes, none of this would have been possible. Their reliableequipment allowed us not only to assemble our wind turbine, but to demonstrate abright future for wind technology.A Brighter Futurewith Konecranes’ HelpCompany Information: ACCIONA, a global leader in alternative energy solutions, hasbeen pioneering renewable energy for over 20 years and is active in all of the fivemajor renewable-energy solutions. For more information about ACCIONA’s AW3000wind turbine, visit www.aw3000.com.
  25. 25. 48 Konecranes • More Happy Customers Konecranes • More Happy Customers 49case study: Branch manager’s perspectiveControls in needof repairWhen this coal-burningpower plant was facedwith a major problem,they immediately calledus. Their original StaticStepless crane controlshad become unreliableand needed to berepaired as soon aspossible. Because wehad been performinginspection repairs at theirfacility for several years,they asked us to quotethe project—and we were awarded the bid over three direct competitors based onour project proposal and ability to complete the project on time.A successful upgradeBecause very few companies know how to repair andmaintain Static Stepless controls, we knew this projectwas going to be a challenge. We sent one of our mostskilled Konecranes technicians to upgrade the crane tonew inverter drives as well as remote controls—but hedidn’t stop there. To improve the crane’s performance,he replaced all gear case and running gear bearings.Without his dedication and technical know-how, wenever would’ve been able to complete the project ontime. Since the upgrade, the power plant has had verylimited breakdowns and has a complete set of spareparts. They were so pleased with our cost-savingupgrade, they asked us to perform the same upgradeon their other turbine crane.Konecranes Wows Facilitywith Crane Upgrade“Konecranes alwaysprovides excellentservice—andlike always, theyimpressed us withthis crane upgrade.Our crane runsbetter than ever andwe are thrilled thatthey’re working onour other crane!”Plant Managercase study: Extreme crane makeoverA serious undertakingWritten from the customer’s perspectiveIt was a critical time or us at the plant. Wewere in a panic because the Departmentof Energy had just posed more stringentrequirements for overhead cranes, whichmeant that our 50-year-old crane wasn’tcompliant anymore. But that wasn’t even theworst of it! We needed to upgrade our craneimmediately, which was going to be challengingfor several reasons: first, the crane wasunbalanced and located in a very tight space,so moving it was going to be tricky. Second,and most importantly, the crane was located ina contamination area—which meant this couldbe a hazardous process. We needed to finda company who could face these challengeshead on and modernize our crane quickly, buteven more importantly, we wanted a companywho could do this with zero safety incidents.Taking charge of the transformationWritten from a Konecranes technician’s perspectiveWe needed to remove the existing trolley from the crane, take it out for disposal andput a new trolley on the bridge—all with limited time and space. The project had apotential for a 1% bonus on the multiple million dollar contract if the work could becarried out with no safety incidents. We were ready to take on the challenge.Dressed in protective gear to shield us from the contamination, we lifted the 40-ton trolley off the girders from below, and then rotate it to bring it down into theconstrained space. Once we removed the girder, the area was decontaminated sowe could do the rest of the modernization in our street clothes. We then installeda new custom-designed crane system that would fit their facility and meet the newstandards. The entire modernization was completed in 11 weeks, and our safe,efficient work earned us the safety bonus.A safer, more efficient workplaceWritten from the customer’s perspectiveKonecranes proved they are the experts in the crane field. They really pulled offa tremendous project here. Our new system has two hoists, designed to performbalanced tandem lifts. Also, they installed a custom hook on our bottom block,so now we can lift all types of containerized loads—no matter the shape, size orsource. Overall, I couldn’t be more pleased with the modernization.Warning! ExtremeCrane Makeover Ahead!
  26. 26. 50 Konecranes • More Happy Customers Konecranes • More Happy Customers 51case study: customer’s perspectiveSeveral months ago, weinvited Konecranes to ourquarterly maintenancemanagement meetingto present a Gear Caseseminar to maintenancemanagers from our nineplants in Oklahoma.Konecranes showedus how important it isto have our gear casesinspected regularly. Wequickly learned in theseminar that small cracksin the gears can lead to serious maintenance and operational matters, including insome instances, unexpected load drop. Unlike other crane issues, this is a “silentkiller;” there’s no noise, no indication whatsoever—the load just drops!Due to age and duty cycle, our cranes were at risk. We decided that each craneneeded an in-depth, open gear case inspection to detect any defects or deficienciesthat cannot be seen during standard visual inspections.We knew right away that we needed to work with Konecranes to develop aninspection plan—we didn’t want to experience a catastrophic failure! So far, wehave had gear case inspections for four of our locations, and inspections are linedup for the rest.Creating a Long-TermMaintenance Mindsetcase studyOne crane at a time...How a Konecranes CraneCan Help Save the WorldTesting massive bladesWind turbine blade testing is critical to maintaininghigh standards of reliability and meeting internationalcertification standards. As they were designing thetesting facility, the Massachusetts Clean EnergyCenter realized they needed an overhead crane totransport the turbine blades to the facility. Theirtesting facility would be the first in the United Statesto allow researchers to test blades up to 300 feet inlength—roughly the length of a football field.The right crane for the jobKonecranes won the order to provide a 50-ton crane,with two 25-ton auxiliary hoists, by providing the mostadvanced features at a cost-effective price. The two-speed crane was equipped with synchronization features, which allowed the hoiststo operate in tandem, maximizing the lifting capacity of the crane.Promoting clean energyWithout the overhead crane, it would be impossible to verify the quality of theblades. The tests reduce the need for costly and time-consuming repairs todamaged blades. Thanks to their successful crane installation, Konecranes hashelped create a future in clean and alternative power generation.Company Information: The Massachusetts Clean Energy Center’s WindTechnology Testing Center is the first in the United States to test turbine bladesup to 300 ft. in length.
  27. 27. 52 Konecranes • More Happy Customers Konecranes • More Happy Customers 53case study: crane detectiveMysterious motor failureFor years, Konecranes had been servicing the cranemotors at an energy-from-waste facility. Suddenly, themotors started failing—in just a few short weeks, five orsix motors mysteriously failed.The Konecranes crane detective takes the caseRight away, I met with the customer and the consultantwho designed the motors to search for clues.The first thing I asked for was a duty cycle analysis.If an employee had been abusing the equipment—like slamming the grapple orsomething of that nature—the report would tell us. Furthermore, if the motors wereexperiencing any type of abuse, I would be able to deduce during which shift thedamage had occurred.I spoke to the plant manager as well. We soon discovered there was a suddensurge of current into the motors—50% more than usual. After calling thePhiladelphia service branch, I determined the spike in electricity was caused by anerror in the controls. After I adjusted the controls, the problem was corrected.Another case closed!The adventures of the crane detective:the Motor Failure Mysteryenergyfrom waste
  28. 28. 54 Konecranes • More Happy Customers Konecranes • More Happy Customers 55case studyPulp & Paper The squeaky monorailThe monorail crane system at the paper plant windsaround the mile-long facility, with sharp turns,similar to a maze. The tight 90 degree corners of thesystem are critical for maneuvering rolls of paperthroughout the building.When employees at the plant began hearing high-pitched squealing noises coming from the crane, theyinstantly began to worry.The self-diagnosisImmediately the plant was convinced the rails were the problem. If this was thecase and the rails needed to be replaced, they would have to shut down the linefor weeks. With downtime costing upwards of $25,000 per hour, the plant was in apanic. Luckily, they called Konecranes to make the emergency repair.The doctor steps inKonecranes sent in one of their most experienced technicians. He diagnosed theproblem in less than two hours: it wasn’t the rails that were the problem—it wasthe wheels, which had worn down and needed to be repaired. Moving quickly, hemade the repairs in as little time as possible, which saved the plant thousands ofdollars in downtime and lost productivity.When Self-Diagnosis GoesWrong, Call Konecranes
  29. 29. 56 Konecranes • More Happy Customers Konecranes • More Happy Customers 57case studycase studyOut with the old, in with the new:New crane nearlyeliminates breakdownsCompany Information: With facilities in more than 20 countries, Ahlstrom is a highperformance materials company that partners with well-known global businesses toprovide products such as filters, wall covers, flooring, labels and food packaging.A crane past its primeThe 40 year-old dry endcrane at an Ahlstromfacility in Brazil was notdesigned to function inthe dusty environmentof a paper mill. Withoutdust-proof enclosuresor air conditioning, theelectrical controls andcomponents deterioratedat an accelerated rate. Thecrane still used its originalcontactor controls, whichdid not have precise speedcontrol options necessaryfor careful load positioning and ultimately caused premature wear to the gears, motorand brakes. As a result, the dry end crane broke down on a monthly basis.Ahlstrom made plans to rebuild the crane, but quickly encountered a majorobstacle: due to the crane’s age, many parts were obsolete and would need to becustom-made. The crane was critical to production and could not be out of servicefor an extended period of time.New crane proves its worthKonecranes successfully demonstrated the value of purchasing a new 20-toncapacity, three-trolley dry end crane. The crane’s sealed enclosures protected againstwater, humidity and dust. The new inverter technology placed less stress on internalcomponents, minimized equipment wear and reduced load sway.To minimize downtime, Konecranes technicians installed and commissioned thenew crane before removing the old crane during scheduled downtime. This strategicinstallation allowed Ahlstrom to remain productive throughout the entire process.Since its installation five months ago, the crane has not had a single breakdown.Not youraverage upgradeA paper company inSouthern Californiaasked Konecranes toinstall a new powerbar system, but therewas a catch: the cranewould need to remainin service throughoutthe entire project.Furthermore, the powerbar was located above the drive controls for the paper machine, which wouldmake accessing the conductor bar difficult.Konecranes devised a plan for their workers to remain safe during theinstallation, keep downtime to a minimum, and meet the tight, 10-day deadline.Successful installed ahead of scheduleThinking creatively, the Konecranes technicians built a workstation platform on thecrane with scaffolding, which gave them complete access to the conductor bar. Toreduce the risk of electric shock while working, the technicians mounted conductorstaff on the end truck and runway rail to maintain constant ground.In the high heat paper mill environment, the technicians replaced the rusted metalclips with more substantial ones, and installed a heavy-duty conductor bar alongthe building. The new four conductor bar system was insulated, finger-safe and metOSHA safety requirements. Konecranes completed the project in only seven days—three full days ahead of schedule.Creative Power Bar ReplacementKeeps Paper Mill Going Strong
  30. 30. 58 Konecranes • More Happy Customers Konecranes • More Happy Customers 59case studyFrom twenty pinches to a single “bite”A paper mill in California previously offloaded woodyard sites with an excavator, which was not efficientfor loading and unloading trucks. The excavator’s setof pinchers took 20 pinches to unload a truck filledwith wood. So, the company decided to try a rotatorcrane from Konecranes, which operates from an 80-foot tall tower on a circular track and can offload anentire truck in a single bite.The paper mill was excited to have the crane—it wouldsave hours every day. There was only one problem: noone in the facility knew how to use it.Konecranes provides hands-on trainingThe Konecranes Training Institute was thoroughlyprepared to train the team on the operation of thecrane. After a presentation on crane safety and an overview of the crane’s features,the employees’ curiosity was peaked. The Konecranes instructors then moved intohands-on operator training where the crew learned how to offload a truck in only twominutes, while maintaining complete control of the load.Konecranes Goes the ExtraMile with Operator Training“Thanks to Konecranes, we not only have quality equipment,but we also know how to operate it safely and efficiently. To me,that’s just as important.”Paper Mill Managercase study: Customer’s perspectiveI would like to senda sincere thanksto our Konecraneson-site managerfor going aboveand beyond at ourpaper plant. Hespoke up about asafety issue whenhe noticed a cordreel electricaloutlet sitting inwater. It should have been on a ground fault indicator, as werequire. If he had not mentioned it, we would not have found it,and one of our guys could have been electrocuted, or suffered aserious electric shock. This went far beyond simply caring aboutour equipment—he was watching out for the safety of the entireplant. We were very fortunate that he spotted this safety issuebefore anyone was injured, and for that, all of us at the plantare truly grateful!Union Chief StewardA satisfied customer shares his storyKonecranes to the rescue
  31. 31. 60 Konecranes • More Happy Customers Konecranes • More Happy Customers 61case studyintermodal& RAILWorking Together to ImproveEfficiency and SafetyA solid, trust-based relationshipThe Huntington Service Branch has built a solidrelationship with the local CSX Locomotive Shopover the past five years. Recently, we sat down withthem to discuss the benefits of Non DestructiveTesting (NDT) of hooks and below-the-hook devices,with a specific focus on the existing 250-tonJ-Hooks that are used to lift locomotives in thefacility. CSX agreed this inspection process wouldimprove the efficiency of their operations and theoverall safety of their cranes.Inspection reveals a cracked hookWe worked with CSX to develop an inspection process that would not interfere withtheir day-to-day business. Our technicians completed the testing of the J-Hooks injust one day.NDT revealed that one of the J-hooks was cracked. The Konecranes inspectorcontacted an engineering office to evaluate the hook and determine whether ornot repairing the hook was a possibility. The engineering department approved therepair, the work was completed over the weekend, and the hook was returned toservice on the following Tuesday.Success leads to proactive maintenanceBecause the repair only caused production to be down for one day, the CSX plantwas extremely pleased with the outcome. To prevent any hook-related issues in thefuture, the J-Hooks for the 250 ton crane are now checked annually. Since the initialrepair, there have been zero lost production days from hook-related issues.Company Information: CSX Corporation, one of the United States leadingtransportation suppliers, provides rail-based transportation services, includingtraditional rail service and the transport of intermodal containers and trailers.
  32. 32. 62 Konecranes • More Happy Customers Konecranes • More Happy Customers 63case studycase study: customer’s perspectiveA major decisionAt our railroad yard, ourtrains and repair shopsnever rest. We stay busy24 hours a day, sevendays a week. With thefast-paced nature ofthe railroad, our liftingequipment needs to bekept in peak condition atall times—we can’t affordto have any breakdowns.So, you can imaginehow frustrated we werewhen one of our criticaloverhead cranes startedvibrating violently. Weneeded to get this crane back into service right away, so we contacted several cranecompanies, hoping to fix the problem as soon as possible. We soon discovered wewere going to have to replace the entire hoist—a repair that was going to be bothextremely expensive and time consuming.We didn’t want to spend the money on a brand new hoist without exploring everyoption, so we called Konecranes for a second opinion. We wanted to make sure thata replacement was absolutely necessary.Konecranes proved to be the right choiceGood thing we called Konecranes, because it turns out we didn’t have to replacethe hoist! Konecranes technicians performed a visual inspection on the open gearcase to find the source of the malfunction. After looking at the gear case, theyshowed us that the gears were improperly timed. In a matter of hours, Konecranestechnicians reassembled the gears into the proper positions.Overall, our decision to call Konecranes was the right one. Their fast repair savedus thousands of dollars and weeks of unnecessary downtime to replace the hoist.Now, our hoist functions properly, and we haven’t had any breakdowns.The Second Opinion that Savedus Thousands of DollarsToo dark...At a busy locomotive shop, workers relied on anoverhead crane to repair locomotives, but the cranecould not be used at night, when the sky was pitchblack. Due to an increase in customer demand, the shopneeded to begin running the crane at night.The shop decided that lights would allow themcontinued use of the crane after the sun went down.So, the locomotive shop ordered two Konecranes jibcranes with 5-ton capacity hoists, with bright lights that shined all night.Too heavy...But, day after day of moving the manual jibs grew tough. The heavy loads grewcumbersome. Productivity began to decline. The shop needed to find a way to makethe cranes more efficient.So, Konecranes modernized the jib cranes to include motors.Just right...The shop now has the proper means to perform the needed tasks thus increasingthe level of productivity at the facility. The motorized jib unit allows the staff toeffortlessly move the materials with precision. In addition, employees were ableto increase the total throughput of the facility by increasing the number of unitsrepaired in a set period of time.The locomotive shop is pleased to have a crane that is just right.Finding the Cranethat is “Just right”
  33. 33. 64 Konecranes • More Happy Customers Konecranes • More Happy Customers 65case studysteel &primary metalsMaking Vintage Cranesa Thing of the PastVintage cranes in need of modernizationAM Castle Metals owned two vintage 20-ton P&H™cranes built in 1968 that were already in place whenthey bought the facility. The cranes ran on open spancopper wires attached to the bridge which poseda potential electrocution hazard to anyone workingaround the crane with a forklift. In addition, theconstant vibration of over 40 years of use had causedbroken wire and switch issues, and parts werebecoming difficult or impossible to find for the wound-rotor controls.Updating cranes with this millennium’s technologyModernization specialists from Konecranes developed a solution. They recommendedreplacing the 1968-era magnetic controls with modern variable frequency drives,designed to provide smooth acceleration and deceleration speeds, reducing wear andtear on the drive train and decreasing load swing.To avoid lost production time, Konecranes scheduled the modernization so theplant experienced no downtime, and both cranes were back in service within aweek. More importantly, a modern festoon system with closed circuit switchingreplaced the open span copper wiring, enhancing the safety of the workingenvironment.Modern crane reduces breakdowns by almost 100%Prior to the modernization, $15,000 was spent in 2008 and again in 2009 on repairand maintenance on this crane. After the modernization, throughout 2010, repaircosts were zero. According to AM Castle Metal’s operations and quality managerJerome Mead, they have not experienced a single breakdown or lost crane hoursince the work was completed.Company Information: AM Castle Metals supplies specialty products in bar, tube,plate and sheet to metal users worldwide.If your crane hasn’t been updated since Nixon waspresident, then it’s probably time for a change.“Konecranes provided us with a much safer way to run ourcranes. We have gained in productivity, safety, and we’ve hadno inspection or detection problems since we’ve done this work.There have also been no repairs whatsoever. In the long run,this modernization is going to save us a lot of money. And whenit comes to safety, we can’t put a price on it. That’s priceless.”Jerome MeadOperations and Quality Manager
  34. 34. 66 Konecranes • More Happy Customers Konecranes • More Happy Customers 67case study: then & nowcase study: salesperson’s perspectiveA Satisfied CustomerShares his storyTo Whom it May Concern:I am writing this letter on behalf of Brannon Steel concerning one of yourtechnicians. I would like you to know that he is one of the most requestedtechnicians for service calls at our facilities at all times. And there are manyreasons for this. Not only are his skills second to none as far as we are concerned,but also his positive attitude and willingness to help make him a delight to workwith. He is constantly giving us advice and teaching us how to better take careof our equipment. I would describe this gentleman as the perfect representativeof your company and we are sure you are very proud to have him and other greattechnicians like him on your staff. When we look for suppliers and service providers,one of the major things we are looking for is people we enjoy working with. So, keepup the good work!Sincerely,Dave LeeSpecial Projects ManagerBrannon SteelCompany Information: Since 1968, Brannon Steel has been an industry leadersupplying quality carbon steel parts to OEMs and custom fabricators throughoutCanada and the United States.Then…This steel manufacturingplant relied on 20 double-girder, top-running cranesand two stacker cranes tohandle slit coil. Installedwhen their facility openedin 1965, these craneswere equipped with single-trolley magnetic five-stepcontrols operated from apendant station. Becausethe plant was onlyhandling coils, a single Chook was enough.Things were about tochange at this plant. They needed to be capable of working with long pieces ofstructural steel and pipe up to 60 feet long—meaning they needed to add a secondhoist to each crane to lift these long pipes. In addition, the plant decided it wastime to upgrade their drives and controls to improve the operation and reliability oftheir cranes.Now…Since they had been providing superior maintenance service and minor craneenhancements to the plant for many years, Konecranes won the bid over threeother companies to complete the upgrade. The plant had confidence thatKonecranes would complete the modernization in a professional manner and ontime. In just six weeks, Konecranes equipped the first of three of the plant’s craneswith rebuilt trolleys, new inverter controls, festoon wiring, bridge motor and gearreducers and radio control. The other two cranes followed immediately after the firstone was finished.Brand new inverter drives allow the cranes to run smoothly and efficiently. Ratherthan using pendant controls attached to the crane, operators are now safer andmore mobile with the new radio controls. The plant is so pleased, they are makingplans to upgrade the rest of their cranes.Konecranes PerformsMuch-Needed Upgrade“Thanks to Konecranes’ upgrades, our plant is more productivethan ever. The new drives and radio controls make it so mucheasier to operate our cranes—and as soon as the new hoistswere installed, we started moving pipes by the truckload.”Plant Manager
  35. 35. 68 Konecranes • More Happy Customers Konecranes • More Happy Customers 69case study: customer’S perspectiveGetting Back onTrack with RailQSix years ago, ourplant was faced withthe challenges of oldequipment: around60% of our productioncranes are over 40years old, which led tomajor crane alignmentproblems, resulting insqueaky wheels. Overall,we used to have a lot ofplant-wide crane issues,and we were constantlychanging wheels, cablesand bearings. When thecranes went down, westopped moving.Konecranes technicians performed a RailQ runway survey, which showed us graphsof the railway alignment. That’s when we found out that the wheels weren’t theproblem. We used to replace crane wheels fairly frequently, but RailQ showed thatwe needed to replace the crane rail in several bays and adjust the elevation. Sincethen, we haven’t needed to replace any wheels.As long as annual inspections continue, we can now expect crane wheels to lasta long time. In any case, I’ll be long gone by then! Konecranes workers, alongwith the RailQ survey, have really made a huge difference. In the past two yearsthere have only been about three times when I’ve had to use my engineers toget a crane working again. Previously, it was every day. Now, we have hardly anyunscheduled downtime.Company Information: The Aluminum Company of America (Alcoa) is the world’sleading aluminum producer, spanning 31 countries and providing services toseveral industries, including aerospace, automotive, packaging, construction andcommercial transportation.case studyGear case implosioncatches foundry off-guardDeep in this hot, dustyfoundry, a 30-year-oldhot metal crane mass-produced nearly 50engine blocks every day.One day, the gear casesuddenly imploded, leavingemployees stunned.“We heard a boomingnoise from the gearcase,” an employeedescribed. “Then thecrane started skewing sobadly, we thought it mightcome off the track!”Because the foundry could potentially lose millions of dollars in lost production time,they gave Konecranes a tight, two-week deadline to complete the massive repair.A crane in desperate need of an upgradeThe problem was obvious to the Konecranes technicians: the crane was performingmore rigorous lifts than its intended design.“It’s not surprising the gear case failed. This was a Class ‘D’ crane performing thework of a Class ‘F’ crane,” explained a Konecranes technician.After upgrading the gearing, the technicians performed inverter upgrades to reducewear on internal components and improve speed control options. As a final boostto enhance safety, the technicians upgraded the radio controls, to function with thenew inverter drives, allowing the operators to lift and tilt the ladle from a distance,keeping them further away from the blazing furnace.Working 16 hour days, the Konecranes team completed the repairs and upgrades inonly 10 days—four days ahead of the deadline. It has been year since the upgrade,and downtime at the plant has significantly decreased.Konecranes Saves anOverworked Crane witha Speedy Upgrade
  36. 36. 70 Konecranes • More Happy Customers Konecranes • More Happy Customers 71case study: branch manager’s perspectiveThe charge ladle crane was commissioned in 2005,but vibration on the main hoist became a problemin the last few years. Eventually, the hoist had to betaken out of service. Several service companies,along with steel plant personnel, could not solve theproblem. Frustrated the issue still hadn’t been fixed,they called Konecranes—the original manufacturerof the crane. After spending thousands of dollars torepair this crane, they wanted another opinion, sowe agreed to take a look at the crane. As the OEM,we had access to all of the documents we needed toassess the situation. After my initial visit, I called the “Crane Doctor,” one of ourbest Engineers, hoping he could provide some insight.Without even looking at the crane, he told me over the phone what he thought theproblem was and assured me he’d be able to fix it. As we drove to the plant, hesaid, “I can’t wait to hear what they have to say when we finally fix this problem.”As soon as he looked at the crane, he showed where the shaft had split due tosevere misalignment. After seven hours of shimming, checking gear mesh andmaking alignment changes to gear sets both vertically and horizontally, the craneran smoothly and quietly. The steel plant was amazed at how quickly and accuratelythe “Crane Doctor” corrected the problem.The “Crane Doctor” SuccessfullyRevives another Crane“This was excellent work done in a very short period of time,and I would recommend this engineer’s services to anybody,anytime to solve very difficult problems.”Steel Plant Managercase study: then and nowThen …Heavy crane causes worker strainThe overhead crane in this facility made the metalfinishing process hard work. Every day, their staffwould gather together to roll the 3-ton, under-runninggirder crane into place. Once the device was pushedinitially, it moved steadily. Unfortunately, as the lawsof physics would explain, once it gained speed it couldbe difficult to stop.The manufacturing process involved two chemicalproduction lines, where parts passed from basketto basket and from tank to tank in order to achievethe appropriate finish. The crane’s movements were not smooth, which resulted inthe metal parts being dropped into the chemical solution—making it necessary foremployees to “fish” out the dropped items.After the metal was dipped into the solution, there was not an effective drainingmethod. Using a forklift, the tubes were removed from the basket and proppedup against a skid to drain. Between the heavy crane and the less-than-idealdraining process, the production process was time-consuming. Customer demandwas increasing, and the challenges derived from the crane were proving to beunacceptable.The metal processing plant desperately needed a new lifting device to enhance thesafety of their employees, improve ergonomics and streamline production.Now …XM Workstation Cranes reduced worker fatigue and improved productionWith two new Konecranes XM workstation cranes with radio pendant controls, thesituation at the plant is much different. Now, the cranes travel the 180 foot lengthof the runway with just the push of a button.The new cranes were easily integrated with existing spreader bars and baskets.The advanced radio controls allow the operator to isolate the hoists individuallyor use them in tandem. By isolating the hoists, the operator can raise one end ofa suspended load higher than the other to drain the tubes directly over the tank,which keeps the floor drier and minimizes solution waste. With better lifting control,the employees no longer have to retrieve dropped items from the chemical tanks.The XM workstation cranes have helped double production at the facility. Instead ofonly coating two items at a time, the new configuration allows for at least four itemsto be processed simultaneously.WLS Crane improvedProductivity withadvanced Ergonomics
  37. 37. 72 Konecranes • More Happy Customers Konecranes • More Happy Customers 73case study: customer’s perspectiveJib cranes not gettingthe job doneIn our manufacturingfacility, we had severaljib cranes that we reliedon to load barrels ofwelding wire onto skids.To keep up with our busyproduction schedule,we need to move about50 barrels a day. Our jibcranes were outdatedand not performingcorrectly. If one of thecranes broke down, wecouldn’t manually lift theheavy barrels. Instead, we had to use fork lift trucks—an operation which was slow,cumbersome, inefficient and unsafe.We knew we needed to upgrade our current system. Since Konecranes had beenperforming our monthly inspections, we decided to contact them and order threenew XM cranes.Konecranes makes vast improvementsWhen Konecranes technicians arrived to install our new cranes, they showed usthat our original cranes hadn’t been installed properly—no wonder we were havingso many problems!Konecranes didn’t stop with the new crane installation. At our plant, we also use amonorail system to load and unload reels of welding wire—but because it wasn’tup to code, we had decided to stop using it altogether. Konecranes extended thesystem and made the necessary repairs so that it was fully functional. Since then,we haven’t had any crane-related issues, and our plant functions better than ever.Konecranes Keeps us on Trackcase study: MANAGER’S perspectiveRapid motor failuresFor the past severalyears, we have beenworking with a steelcompany that operatesclass E cranes in ahigh heat environment.Konecranes Crane ProParts motor shop hadbeen servicing theirpowerful crane motorsto keep the cranes in topcondition. So, when someof the rebuilt motorsbegan to fail within daysof installation, we had towork quickly to determinethe cause.Finding the root of the problemI dug into the problem, along with a salesperson and an outside motor designconsultant. We discovered the motors were experiencing problems because thecontrols were not set up properly. Our service technician came in over a holidayweekend to check the controls set-up, test in-rush currents and examine othercritical values. He made several adjustments to the controls during the visit thathave improved the service life of the rebuilt motors.In addition, we suggested the customer improve the cooling and brushes on themotors so they could stay in top condition and would be less likely to break down.Restoring Life toHigh-Powered Motors“Thanks to Crane Pro Parts, our motors are performing at amuch higher level and are lasting a lot longer—and we areconfident our cranes are in the best hands possible.”Plant Manager

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