Protect your Heavy Equipment Investment
Training Workers Adds to the Bottom Line and Keeps Everyone Safe

By Radley West

What is the most expensive factor in your production facility? Most likely you immediately thought of lost productivity. What is the root cause of most issues of lost productivity? The answer is . . . people. More specifically, it is people who don't know what they're doing. That's right, under-skilled employees have a direct impact on your facility's profitability.

When your production facility requires the use of heavy lifting equipment, such as overhead cranes or hoists, operator skill set is vitally important. Not only can a poorly trained operator cost you millions of dollars in lost production time but he can cause lost time accidents costing you millions more in safety violation charges and workers' compensation claims.

According to industry-wide statistics, 70 percent of all repairs to or caused by overhead lifting equipment could have been avoided with proper operator training. Human error accounts for premature equipment wear and tear, dropped loads, and crane downtime. In some areas, occupational health and safety regulators require operators be trained and issued a permit from their employer. It is imperative you make sure your operators, crane inspectors, maintenance technicians and safety personnel are properly trained in the proper care and use of your overhead equipment.

Additionally, 72 percent of all accidents related to overhead lifting equipment could be eliminated with a comprehensive training program. Human error is the most common cause of hoist and crane accidents. Thus, careful training of crane or hoist operators must emphasize safe operating procedures that go beyond those actions required to operate the hoist. Often, hoists are loaded beyond their capacity or loads are not balanced. Other times, people walk beneath a load or fail to communicate with the operator using predetermined signals. The consequences, although avoidable, can be devastating.

Large hoists having a capacity of five or more tons typically employ electric- or air-powered motors. Smaller chain hoists can be manually powered, with operators grasping and pulling continuous hand chains to operate the hoists. No matter what the power source, a normally safe hoist in the hands of an untrained operator or an employee who ignores safe operating procedures represents a potential workplace hazard. There are many variables to safe hoist operation, but the most important is knowledge--about the hoist, the load, and safe operating practices--as well as the training and communication that support that knowledge.

Training should include a discussion of balanced lift points and safe rigging practices. Slings or other attachments should be seated in the saddle of the hook and safety latches should be present and functioning properly. The hoist's load chain or rope should never be used as a sling. Be certain the chain or rope is straight and properly seated in the load sheave and, unless the hook is specifically designed for point loads, avoid tip loading. Loads should always be lifted slowly at first to make certain everything is seated and operating properly. They should also be lifted vertically, avoiding side pull, which places additional stress on the hoist, risks uncontrolled load swings and causes unnecessary wear and tear on the drum. Once properly trained, employees need to be held accountable for undue repairs and accidents caused by neglect or disregard of safe operating procedures.

A study done by the American Society of Training and Development shows that companies that invest $1500 per employee in training, compared with those that spend just $125 per employee, enjoy on average a 24 percent higher gross profit margin and a 218 percent higher income per employee. Add those figures to the potential savings from less repair costs, lower accident rates and increased productivity, and your profitability will skyrocket. These days as we all try to do more with less, training makes good fiscal sense.

Even if operators observe safe practices and use common sense, accidents can still happen if the hoist itself is neglected. OSHA requires that all lifting equipment be regularly inspected according to standards set by the individual manufacturer and ANSI. An inspection program that includes proper maintenance is advantageous to the company and its employees. The program should help prevent any lost-time accidents resulting from equipment failure and should prolong the life of the hoist. It is important to choose a qualified, certified technician to inspect your equipment, ensure its safety and verify it is in proper working condition. Most quality inspectors can help you learn about potential problems or failures before they occur, thus saving you money by eliminating costly downtime.

Moving large, heavy loads is crucial to today's manufacturing. There are significant safety issues to be considered, both for the operators of the diverse lifting devices, and for workers in proximity to them. A thorough inspection and maintenance program, when coupled with a comprehensive safety and training program geared toward proper and safe crane and hoist use, can provide a safer working environment and can help you get the most out of your crane or hoist investment while maximizing your uptime.

Radley West is a regional manager with P&H Cranes/Morris Material Handling, a Wisconsin-based manufacturer of Overhead Industrial Cranes and Hoists. The Institute of Morris Material Handling offers training in the field of cranes and hoists and instructors have more than 65 years of combined experience in overhead material handling. For more information visit www.morriscranes.com.