Crane Modification and Relocation
Industry:
Automotive Manufacturing
About the Customer:
A $1.8 billion organization headquartered in Maharashtra, India, is a Tier 1 supplier to the automotive industry, primarily focused on polymer components, exterior lighting systems, plastic, and electronic components for passenger and commercial vehicles. With a global presence, the company operates multiple manufacturing facilities across India, producing critical parts for various automotive brands.
The Backdrop:
The customer decided to close their Patherdi plant to streamline operations and enhance efficiency. The plant was equipped with two overhead cranes, each with lifting capacities of 25/10t and 20/10t, respectively, and used extensively in the stamping line. As part of their reorganization strategy, the manufacturing processes from Patherdi were to be shifted to newer facilities in Pithampur and Pune, both designed to accommodate similar equipment.
The Challenge:
The new Pithampur facility had a wider bay compared to the Patherdi plant, necessitating a modification to the crane’s span to fit the new space. Specifically, the crane span required a 400mm extension to match the dimensions of the Pithampur shed. Additionally, the relocation process demanded the dismantling, modification, and re-installation of the crane within a tight 4-week timeframe, without disrupting production at the new site.
The Expectations:
The customer sought a reliable service partner to oversee the entire process, from removal and dismantling to modification and installation. Having successfully managed a previous crane relocation, the customer placed their trust in the service provider’s expertise to complete this project within the stringent timeline while minimizing costs.
The Solution:
With a team of over 60 service experts stationed across India, the service provider quickly assigned personnel for supervision, dismantling, and loading at the Patherdi site. The crane components were transported in two trailers: one trailer, containing crane kits, was sent directly to the Pithampur site, while another, with girders and end carriages, went to the Pune facility for the required span modification.
To modify the crane, an additional 200mm section was welded to each end of the girder using splice joints, followed by a dye penetration test to ensure structural integrity. After the modification, the crane was tested for load capacity per industry standards. Once all specifications were verified, the crane was reassembled at Pithampur, installed with utmost safety, and load-tested at 100% and 125% of rated capacity. The installation was successfully completed on time, without any production loss.
A Statement of Overall Benefit:
The service provider’s efficient execution, skilled personnel, and logistical coordination allowed the customer to optimize existing assets and save significantly on capital expenditure, demonstrating a well-orchestrated solution for complex industrial modifications.
Benefits:
- 80% Reduction in Capital Expenditure: Leveraging the existing crane with minimal modifications avoided the cost of purchasing a new one, saving approximately ₹50L.
- Optimal Use of Existing Assets: The modification allowed the customer to utilize the crane in a new facility without major investments.
- Time-bound Project Execution: Completed within the 4-week schedule, ensuring production continuity at the new site.
- Enhanced Safety and Compliance: The crane installation met all IS standards, with successful load tests ensuring reliability and safety.
- Manpower Cost Savings: Quick mobilization of nearby service personnel reduced labor costs and expedited project completion.