Restoring Stability and Safety for Heavy-Duty Crane Operations in High-Force Press Applications

Industry:
Automotive Manufacturing

About the Customer:
A global automotive manufacturer with operations in India since the 1980s, this company operates two major facilities in Chennai and Sanand. Spanning 350 acres, the Chennai plant produces entry- and mid-level SUVs and engines. The company is known for its high standards of operational efficiency and safety, especially in its heavy-duty manufacturing and press blanking lines.

The Backdrop:
The Chennai facility’s press blanking line, a high-force operation area, is equipped with several decade-old heavy-duty double girder EOT cranes with capacities of 65 tons and 50 tons, respectively. The cranes span 30 meters with a height of lift (HOL) of 18 meters, operating across a 150-meter bay length that houses multiple hydraulic presses. These presses exert a continuous downward force that, over time, has caused a level difference between the two crane gantries—exceeding permissible tolerance by 7-8 times.

The frequent, substantial force exerted by the press machinery resulted in severe wear on the crane’s wheels, necessitating quarterly wheel replacements and incurring significant costs and downtime. Additionally, one near-miss incident involving crane derailment raised urgent safety concerns. The facility’s management sought a solution that would restore crane stability, improve safety, and eliminate the frequent breakdowns within the shortest possible timeframe during a planned 21-day shutdown.

How Sparkline Was Selected:
Sparkline had previously installed a series of interconnected automated cranes at the company’s Sanand facility. Based on Sparkline’s track record and as an authorized partner with specialized expertise in resolving crane-related challenges, the company reached out to Sparkline for support in addressing the structural and operational issues impacting the Chennai plant’s crane systems.

The Challenge:
The press blanking line faced critical challenges due to:

  • Significant Structural Misalignment: The level difference between gantries led to frequent wear on long travel (LT) wheels and posed a high risk of derailment.
  • Safety and Reliability: Safety concerns were heightened due to a near-miss derailment incident. Regular crane breakdowns also posed a financial and operational burden.
  • Time Constraints: Sparkline was tasked with completing the entire dismantling, repair, and reinstallation process during a 21-day shutdown, with the complexity compounded by limited access due to surrounding floor machinery.

The Solution:
To address these issues, Sparkline provided a comprehensive overhaul, including dismantling, realignment, structural correction, and reinstallation of the crane system. The solution involved several key steps:

  1. Detailed Planning and Preparation: Sparkline submitted rigging, dismantling, and re-erection plans, which were thoroughly evaluated and approved. A team of 43 service experts, including 9 engineers, was assigned to ensure all work would meet the 21-day timeline.
  2. Dismantling and Inspection: Initial dismantling of the cranes uncovered additional structural issues, including a twist in the bridge girder and a 50 mm difference in span across the bay, which contributed to repeated wheel wear and rail damage. The main components, including end carriages, LT motors, and the crane crab, were removed for inspection.
  3. Rail Replacement and Alignment Correction: The existing gantry rails were heavily worn due to misalignment and high friction. Sparkline replaced the entire CR100 rails across the 150-meter bay length, ensuring precise installation. After realigning the gantry and correcting the span difference, Sparkline restored the structural integrity needed for reliable crane operation.
  4. Structural Reinforcement and Component Replacement: The twist in the bridge girders was corrected onsite with the support of the customer’s team. Sparkline installed new end carriages and high-quality wheels designed to withstand heavy-duty press applications, ensuring long-term durability and reduced maintenance needs.
  5. Load Testing and Certification: Following the reassembly, the crane was load tested to certify its safe operation in the high-force press blanking area. Sparkline completed the entire project within 18 days—three days ahead of schedule.
  6. Post-Implementation Monitoring: For several months following installation, Sparkline monitored wheel wear using a specially designed gauge to confirm stability. Results showed negligible wear, demonstrating that the alignment corrections and component replacements effectively eliminated recurring issues.

A Statement of Overall Benefit:
Sparkline’s comprehensive, precision-driven solution restored the stability, safety, and efficiency of the customer’s press blanking crane system. Completed within the scheduled shutdown period, the project eliminated recurring breakdowns, reduced maintenance costs, and ensured zero production loss.

Benefits:

  • Zero Production Loss: The work was completed within the planned shutdown, allowing uninterrupted production once operations resumed.
  • Cost Savings on Maintenance: With the alignment issues resolved, the company avoided annual maintenance costs of approximately ₹5 lakh, previously spent on frequent wheel replacements.
  • Increased Safety and Reliability: The reinforced structure and precise alignment corrections significantly reduced safety risks, ensuring stable crane operation without derailment incidents.
  • Long-Term Durability: The crane system has operated without breakdowns for four years since the overhaul, affirming the lasting impact of Sparkline’s solution.

Through rigorous planning, efficient execution, and strategic structural improvements, Sparkline transformed the customer’s heavy-duty crane operations into a safe, reliable, and cost-effective system, meeting the high demands of the press blanking line.