Despite the fact that many economies appear to be clawing their way back to something that resembles a healthy position, the pressure on capital expenditure is set to continue and be relatively constraining.
Where lifting and materials handling equipment is concerned, most production, manufacturing and operational managers/directors would probably prefer to see their operations continue to invest in new technology. However, this is not always the best course of action, and any supplier to the lifting business worth their salt has a duty of care to help present the best options dependent upon a whole host of criteria.
Not surprisingly, one strategy that is proving to be particularly popular and effective across an increasing number of industry sectors is crane modernisation. This not only helps solve the dilemma of budgetary constraints that can impact adversely on new equipment purchases, but can also prove to be just as an effective tool in providing the latest productivity, technology and safety standard advances, but at a fraction of the cost.
Total cost of ownership
The objective of the exercise here is to focus on cost savings using an approach known as Total Cost of Ownership (TCO). This process centres on using the specialist skills of your lifting equipment supplier to provide a detailed examination of older equipment as a means of determining the requirement for upgrades in order to maximise both operating efficiencies and investment.
Crane modernisation programmes ultimately help companies lift more material, more efficiently and faster; sometimes providing additional production capacity. As systems age, production can slow. Also, ageing cranes may require more maintenance, whereas modernised ones typically need less maintenance.
Overall - and this isn’t rocket science - such an approach delivers a better return on investment in the medium and long-term, maximising the all-important TCO. Furthermore, modernisations take into account any recent changes to regulations and safety standards, which can help keep a company safe and compliant and less likely to be involved in any liability claim.
Modernisations also often build upon the existing structure and viable component parts of the original equipment. In many instances, modernisations can be performed many times on a piece of heavy-duty lifting equipment to substantially extend its lifespan and useful service. Furthermore, most modernisations can be undertaken in planned stages; this reduces the incidence of unscheduled downtime and may fit better with budget commitments.
The process
Before recommending any form of crane modernisation, a lifting equipment specialist will take an inventory of performance needs and examine the reliability of existing structures to identify any potential safety issues. They should also examine the condition of parts and recommend replacing those that are clearly worn. Armed with this information, they should then recommend the most cost-efficient upgrades that are required, but always keeping in mind the existing materials and structure.
This process often involves replacing worn-out and obsolete parts with next generation components. In addition, modernised cranes can benefit from the latest automated technology, new electric drives and control systems that are capable of combining accurate positioning with improved speed performance for optimal productivity. Furthermore, crane modifications can now take advantage of modern radio control systems, ergonomic control panels, power supply packages, retrofit inverter controls and load limiters.
Crane modernisation schemes broadly fall into one of two categories: pre-engineered upgrades and engineered crane modernisations. The former sees upgrades and smaller improvements being applied to equipment conveniently at a customer’s site or sites.
These upgrades generally improve crane functionality and are designed to minimise the incidence of failures, with all their ensuing cost implications. Commissioning is done in a planned manner and within a short time frame to minimise disruptions to production. Pre-engineered modernisations can include hoist replacements or other upgrade packages such as overload protection.
Engineered modernisations are projects for overhead cranes and port cranes. Here experts in crane electrics, mechanics, and automation combine their expertise to deliver a complete and often turnkey modernisation project.
When considering what the best option may be when it comes to replacing or modernising lifting equipment, it is worth keeping in mind the old adage ‘forewarned is forearmed’. Maintaining or increasing productivity can often be achieved just as effectively through the process of crane modernisation, but before choosing what is exactly the best course of action, get some advice from the specialists in this field.
Derek Hicklin is commercial and development manager at Konecranes