Presenters: Mike Brunet, Dan Snook, Brian Hill, John Alexander, Scott Mohn and Gary Herrmann

Guidelines for Good Clean Livin’ SC&RA webinar

Roundtable topics

• Employee training and education

• Proper preventative maintenance

• Advantages of using telematics

• Overload occurrence

• Structural repairs

Employee training & educationMike Brunet Product safety director, Manitowoc Cranes

Getting serious about employee engagement

Were your employees engaged in 2011?

Gallops and Towers Watson results show:

• 29% are fully engaged

• 54% are partially engaged

• 17% are actively disengaged

Benefits of employee engagement

Companies with engaged employees experience:

• Less turnover

• Higher than average client retention

• Above average productivity

• Safe work environment

• Higher profitability

• Create engaging training and development programs

• Ensure training is compelling and ongoing

• Set goals and get performance feedback

• Get company leaders on board

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Employee development

Group A: high school graduates and tech school graduates have volunteered for rigorous positions in a variety of marine operations.

Group B: representing the future, arrives at front door for 1st day of training/new employees, get greeted, and are ready for grueling instructor-led training (or “death by PowerPoint”)

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A Tale of Two Worlds

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A Tale of Two worlds, cont.

Group A: joined organization with long history of high, short term personnel turnover

Organization A: relies on immersive training involving gaming and virtual worlds

Group B: employed by an industry sector known for rapid boom/bust cycles – gas and oil, construction

Organization B: relies on traditional methods

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How long to train experts?

•One school of thought suggests experts require 10,000 hours of work in the field:

8 hour day, 5 days/week = about 1,920 hours/yr x 5 years

•Full trained team member in 1.5 years requires increased training by 347%

•Group A has been trained at this accelerated rate since 1775

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Compare to traditional industrial training

• Group B training led by competent subject matter experts

• Impart their knowledge in a format that dates back to 1775 – The CLASSROOM

• Classroom is still a viable tool, but it must be augmented

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Been There, Done That

Better to learn and make potential, catastrophic life threatening mistakes in a classroom or simulator

Do you want workers engaged in real situations to make near instantaneous decisions and thinking “I have never seen this before”?

•Over the ocean at 40,000 ft., pilot says “do not worry, we have not encountered this situation before”

•“Houston, we have a problem….”

•“I signaled Pick the load up, why is the load moving to the left, trapping me against the wall…”

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Been There, Done That, cont.

Imagine news media interviewing your operator, rigger, signal person, who is cool and calm, saying, “This is just part of my job – no big deal.”

This response is largely because of training:

Been There, Done That

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Important assetsBig bucks and careers on the line

Refinery turnarounds, sports arenas, building the Freedom Tower, putting the space shuttle on the aircraft carrier…

These tasks will come to screeching halt without competent men and women necessary to:

•Assemble the equipment

•Maintain the equipment

•Operate the equipment

•Rig and move the loads

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Legal Responsibility

Board members and top executives may have personal culpability if discovery process exposes personnel competency management issues.

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Training Summary

Now, more than ever, trained, high performing operators, riggers, signal people, technicians are truly required for long-term success.

Two questions:

1.Why would a new hire want to come work for your organization?

2.Without trained operators, riggers, signal people, and technicians, what is the future value of your organization?

Proper preventative maintenanceDan Snook Corporate training, MTU/MercedesBrian HillField service manager, Manitowoc Crane Care

Why follow the manufacturer’s maintenance recommendations?

•Decrease cost of operation

•Avoid downtime

•EPA compliance

•Record keeping

•Approval of fluids and lubricants

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Maintenance recommendations

The following are especially important:

•Use of proper oils as recommended

•Coolant recommendations

•Air intake

•Fuel system

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Maintenance recommendations, cont.

Following recommended maintenance intervals will help maintain the safety, dependability, and productivity designed into your crane.

•Intervals are based on average operating conditions

•Can and may be adjusted to meet the specific operating conditions of your crane

•Observe crane performance before adjusting intervals

•Perform oil analysis at to refine oil-change intervals19

Recommended maintenance intervals

•Maintenance and inspection intervals are based on hours of operation or calendar based intervals.

•Daily or 8 hour inspections are typically visual and operational inspections. Fluid level checks may also be included.

•Daily or 8 hour inspections are critical to complete as they could detect small issues prior to becoming a major issue.

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Maintenance intervals

Required weekly, monthly and quarterly; will become more in depth and may require more effort to complete, however their completion is critical in maintaining a safe and properly functioning crane.

•To ensure complete and thorough inspections, manufacturers will commonly include checklists with crane documentation.

•Manitowoc Cranes has newly reformatted maintenance and inspection checklists along with Service logs to assist Crane owners in complying with new Federal regulations.

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Maintenance and inspections

SC&RA Webinar Crane Care - Guidelines For Good Clean Livin'

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Maintenance and inspections

SC&RA Webinar Crane Care - Guidelines For Good Clean Livin'

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Maintenance and inspections

Advantages of using telematicsJohn Alexander CraneSTAR/Technical Communications Director, Manitowoc Crane Care

The world of crane “telematics” seems populated with several types of fleet owners.

• In the minority are a few who are developing systems aimed at integrating the data into business systems for improved fleet management.

• In the majority are those who either don’t fully understand the technology or who question its value, cost and return on investment.

• In the middle are those who understand telematics, but aren’t quite sure about how to best integrate the technology into their businesses.

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Telematics and the crane industry

How much machine data will you use?

•For the 10 to 20 percent of heavy equipment asset managers who use telematics data, working with vast amounts of data often seems not worth the effort.

•If you talk to telematics users you might be surprised at how little information is actually used to efficiently manager their fleet.

•“If it ain't broke, don't fix it”. In the days when machinery was simpler to troubleshoot and fix, that philosophy worked fine. Today the more appropriate philosophy is: “If it ain't broke, lets work to keep it that way”.

•An effective preventive maintenance program helps…and Telematics provides your PM program with accurate machine information.

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Telematics and CranesData vs. Information

Maintenance optimization

•A recent study concluded that the return on investment in preventive maintenance on heavy equipment can be as high as 500%, with the bulk of the return coming from increasing the equipment's useful life. For a crane, this can be significant.

•With the improved accuracy and near-real-time availability of engine hours and system alerts, telematics enables companies to successfully fine-tune PM service.

Asset Utilization

•Lift Reports – The availability of lift data allows the fleet manager to monitor the correct operation of a crane to the manufacturer’s specifications. This again assists the “informed” asset manager to allow for the extended useful life of his equipment.

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Telematics and CranesExtended Machine Life

Overload occurrenceScott Mohn Mobile crane service operations director,Manitowoc Crane Care

Overload: Any load lifted that is beyond the rated capacity as outlined on the crane load chart.

Why be concerned about overloads?1. Accidents 2. Structural damage

– Gross overload (noticeable immediately)– Minor overload (long term damage)

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Overloads

In the event of an overload, refer to the operators manual.

• Inspection requirements for overload checks are broken down into 3 areas of inspection, by percentage overload:

– Boom (0-25%, 26-49%)– Super Structure (0-25%, 26-49%)– Carrier (0-25%, 26-49%)

• These inspections are only for overloads up to 50% overload. Anything beyond 50% requires the user to contact the manufacturer for further instruction.

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Overloads

Overload inspectionThis information supplements the Load Moment Indicator (LMI) manual supplied with each Grove crane. When the LMI system has acknowledged an overload on your crane, you must carry out specified inspections on the crane.These inspections apply only to overloads up to 50%. For overloads of 50% or higher, crane operation must be stopped immediately and Crane Care must be contacted for corrective action.

NOTE: If your crane is equipped with CraneSTAR, an overload warning will be posted to the web site for review by the crane owner.Overload warnings do NOT indicate real time events! Warnings could be sent 24 hours (or more) after the actual event.

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How to address overloadsOperator’s manual

 WARNING

Overload Hazard!

To avoid an accident caused by overload damage to your crane:

*Perform the inspections outlined in this publication for overloads up to 50%.

*Stop operating the crane and contact Crane Care immediately for overloads of 50% and higher.

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Boom inspections

Overload less than 25%

1 Sheaves Inspect all for damage.

2Luffing

Mechanism/CylinderInspect for damage/leaks.

3 Collar-wear pads Inspect all for damage.

Overload from 25% to 49%

1 Sheaves Inspect all for damage.

2Luffing

Mechanism/CylinderInspect for damage/leaks.

3 Collar-wear pads Inspect all for damage.

4 Collar-welds Inspect all for cracks.

5 Telescopic SectionsInspect for bent or twisted sections. Check

the boom for straightness.

6Lift Cylinder Head

AreaInspect for bends or cracked welds.

7 Turret-Base Section Inspect for cracked welds.

8Locking Area (Pin

Booms)Inspect for elongated holes.

9 Welds Inspect for cracks.

10 PaintInspect for cracked paint which could

indicate twisted, stretched, or compressed members.

• Safety

• Longevity of Crane

• OSHA compliance

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Benefits of following guidelines

Structural repairsGary HerrmannStructural engineer, Manitowoc Crane Care

When a repair is required, why should you request repair instructions from the manufacturer?

•Get a Proper Repair

•Maintain Equipment Value

•OSHA Requirements

•Liability

•Product Improvement

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Involving the manufacturer

All steels are NOT created equal.

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Proper repair

Your equipment will better maintain its value if repairs have been done correctly in accordance with the manufacturer’s instructions.

SC&RA Webinar Crane Care - Guidelines For Good Clean Livin'

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Maintain equipment value

Requirements for load sustaining structural components in OSHA CFR 29 Section 1926.1412(b)(1)”

•Load sustaining structural repairs must be inspected by a qualified person

•The qualified person must determine if the repair meets the manufacturer equipment criteria

•There are other options available, but they do not apply if the manufacturer equipment criteria are available

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OSHA

Limit your liability!

•Follow the OSHA requirements in 1926.1412(b) (1) (i)

•Contact the manufacturer for repair authorization

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Liability

•Sometimes the manufacturer may have already developed a kit that can be used.

•At the very least, it gives the manufacturer the ability to look at repetitive or trending repairs needed and potential future improvements.

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Product improvement