About to Operate Overhead Lifting Equipment? Follow These Safety Guidelines

By the members of MHI’s Overhead Alliance, which is comprised of the Crane Manufacturers Association of America (CMAA), the Hoist Manufacturers Institute (HMI) and the Monorail Manufacturers Association (MMA).

One of the best ways to keep overhead crane, monorail, and hoist operators — and the personnel working around the equipment — safe is to train them to follow best safety practices. The members of the Overhead Alliance publish multiple checklists and guidelines, including a “Pre-Operational Equipment Check of Cranes and Hoists” developed in conjunction with the Occupational Health and Safety Administration (OSHA). This publication details 13 separate areas for operators to inspect prior to using the equipment.

Additionally, all three Overhead Alliance industry groups — The Crane Manufacturers Association of America (CMAA), the Hoist Manufacturers Institute (HMI), and the Monorail Manufacturers Association (MMA) — publish guidance for performing pre-shift equipment inspections. Each also offers overhead lifting equipment “Dos and Don’ts.” Following these recommendations enhances both the integrity and reliability of the equipment, as well as reduces the risk of injury for workers operating or working in proximity to it. The information is complimentary and available via each group’s website.

PRE-SHIFT INSPECTIONS CREATE SAFER OPERATIONS

Following recommendations from MHI’s Overhead Alliance can enhance the reliability of lifting equipment and reduce the risk of injury for workers operating in proximity to it. © chibelek – stock.adobe.com

There are several key areas to assess when performing a pre-shift inspection of overhead lifting equipment, noted Matthew Frazier, Senior Manager of Engineering in New Product Development at HMI member Columbus McKinnon.

“First, only permit a qualified, trained person — usually the operator — to perform the pre-shift inspection,” Frazier said. “The inspection includes both visual and auditory assessments. Therefore, the operator needs to know what to look for and how the equipment usually sounds when it’s running.”

Frazier pointed out several key areas to assess:

• Is an out-of-order or out-of-service tag attached to the equipment?
• Are the warning labels present and intact?
• Do actual hoist, trolley and bridge motions agree with those marked on the controller?
• Are the hook and latch working properly or are they damaged or deformed?
• Is the wire rope broken, kinked, or improperly wound?
• Is the load chain not worn, stretched, twisted, or distorted?
• Do the braking and travel limits and limit switches function properly?
• Are there any abrasions, wear, or weld splatters on the equipment that could inhibit its operation?
• Does the equipment make any unusual sounds in operation?
• Are there any signs of oil leaks on either the equipment or the floor?
• Are there any obstructions in the surrounding area or travel path of either the operator or the hoist that could pose a hazard?

If the equipment fails any of the inspection points, operators should notify their supervisor, and the equipment should be tagged as “out of service” until the issue is resolved.

“The pre-shift inspection should also include any guidelines or areas for assessment recommended by the manufacturer of the equipment,” Frazier added. “Those are in the equipment owner’s manual.”

Also, the operator should document the findings of every pre-shift inspection, either on paper or electronically. The facility should retain those records to confirm that inspections are being performed, as well as to identify any areas of concern or patterns of wear.

In addition to pre-shift inspections, it is critical to establish a schedule of frequent and periodic inspections to identify wear and preventive maintenance needs. Doing so ensures both operational safety and maximum service life of the equipment. Facilities needing more help with establishing inspection processes for their overhead equipment can connect with the Overhead Alliance.

OTHER SAFETY BEST PRACTICES WHEN OPERATING OVERHEAD LIFTING EQUIPMENT

In addition to pre-shift inspections, CMAA, HMI, and MMA recommend several safety measures when operating overhead lifting equipment. Among them are:

• Understand the duty cycle (frequency of use, type of load, and average load weight) of the lifting application when specifying/purchasing the equipment. While it may cost more, equipment sized for the task will last longer and not require premature replacement of motors, brakes, electrical components and other key mechanisms.
• Perform regular preventive maintenance as specified by the crane manufacturer to ensure long service life. If outsourcing this work, engage independent crane service and inspection professionals with experience on the specific equipment.
• Only allow personnel who have been trained on the proper use of the overhead lifting equipment to rig loads for it and operate it. Require operators to follow all of the manufacturer’s safety precautions when operating the equipment.
• When operating the equipment, do not attempt to lift a load that exceeds its capacity rating. Further, never slam the bridge or trolleys into the end stops; doing so will cause premature wear on the equipment.

GET MORE OVERHEAD LIFTING SAFETY GUIDANCE

Overhead Alliance members CMAA, HMI, and MMA are dedicated to enhancing the safety of overhead lifting equipment and operations. To that end, the organizations produce a variety of training materials and other educational resources for equipment owners and users. Visit their websites at mhi.org/cmaa; mhi.org/hmi; and mhi.org/mma for access to operators’ manuals, safety tip sheets, fact sheets, quick cards, webinars, and other materials to enhance the safety and productivity of your facility. WMHS

MHI’s Overhead Alliance (mhi.org/overhead-alliance) — a joint collaboration of the Crane Manufacturers Association of America (CMAA, mhi.org/cmaa), the Hoist Manufacturers Institute (HMI, mhi.org/hmi), and the Monorail Manufacturers Association (MMA, mhi.org/mma) — provides information about the benefits of overhead lifting in industrial applications. It also produces educational videos, sponsors safety-focused educational seminars and webinars, and shares details about the latest technological developments in the field. Additionally, the group works with the Occupational Safety & Health Administration (OSHA) as the Crane, Hoist, and Monorail (CHM) Alliance Program Ambassador (mhi.org/chm). Through this partnership, the two organizations provide information, guidance and access to training resources that help protect the health and safety of worker using hoists, cranes, and monorails.