Happy Customers - Konecranes ... 12 Konecranes ¢â‚¬¢ More Happy Customers...

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Transcript of Happy Customers - Konecranes ... 12 Konecranes ¢â‚¬¢ More Happy Customers...

  • Konecranes • More Happy Customers 1

    Happy Customers AND OTHER SHORT STORIES FROM 2012

  • 2 Konecranes • More Happy Customers Konecranes • More Happy Customers 3

    MISSION

    Not Just LIFtING tHINGs, But eNtIre BusINesses

    VISION “We know in real time how millions of lifting devices and machine tools perform. We use this knowledge around the clock to make our customers’ operations safer and more productive.”

    VAluES Trust in People We want to be known for our great people.

    Total Service Commitment We want to be known for always keeping our promises.

    Sustained Profitability We want to be known as a financially sound company.

    STRATEgIES > Differentiation through service

    and technology innovation > Lifting people > Global footprint and supply chain > Dual-channel > Real-time information

  • 4 Konecranes • More Happy Customers Konecranes • More Happy Customers 5

    CoNteNts AuTOMOTIVE Automotive Stamping Plant ................. 7 Automotive Stamping Plant ................. 8 Assembly Factory .............................. 9 Engine Assembly Plant ..................... 10 Automotive Facility .......................... 11

    gENERAl MANuFACTuRINg Leading Manufacturing Company ...... 13 Concrete Company ........................... 14 Manufacturing Facility ...................... 15 Manufacturer of Automobile Interior Mechanisms .................................... 16 K.K. Tool Company .......................... 17 Toyota Lift of Minnesota ................... 18 Manufacturing Facility ...................... 19 Piper Valve Systems ......................... 20 Manufacturing Facility ...................... 21 Schlumberger Technology Corp. ........ 22 Automated Material Handling Facility ... 23 Component Manufacturing Facility .... 24 Manufacturing Facility ...................... 25 Brewery ........................................... 26 Chemical Plant ................................. 27 Offshore Drilling Components Manufacturer ............... 28 Bottling Factory................................ 29 Pound Cake Factory ......................... 30 Fabrication Plant .............................. 31 Toyota Material Handling .................. 32 Electrical Components Factory .......... 33 Christie ........................................... 34 Tencate Advanced Armor ................. 35

    MACHINE TOOl SERVICE Patterson Pump ............................... 37

    PETROCHEMICAl Engineering Company ....................... 39 Houston, Texas Oil Refinery .............. 40 Oil Refinery ...................................... 41

    POWER Los Angeles Department of Water and Power .......................... 43 Hydroelectric Plant ........................... 44 Hydropower Plant ............................. 45 Los Angeles Department of Water and Power .......................... 46 ACCIONA ......................................... 47 Coal-Burning Power Plant .................. 48 Power Plant ......................................... 49 Power Plant .............................................50 Massachusetts Clean Energy Center’s Wind Technology Testing Center ........ 51

    ENERgY FROM WASTE Energy-From-Waste Facility ............... 53

    PulP & PAPER Paper Plant ...................................... 55 Ahlstrom ............................................. 56 Southern California Paper Company .. 57 Paper Plant ...................................... 58 California Paper Mill ......................... 59

    INTERMODAl & RAIl CSX Corporation .............................. 61 Railroad Yard ................................... 62 Locomotive Shop ............................. 63

    STEEl & PRIMARY METAlS AM Castle Metals ................................ 65 Brannon Steel.................................. 66 Steel Manufacturing Plant ................ 67 Foundry ........................................... 68 Alcoa............................................... 69 Metal Processing Plant ..................... 70 Steel Plant ...................................... 71 Steel Company ................................ 72 Manufacturing Facility ...................... 73

  • 6 Konecranes • More Happy Customers Konecranes • More Happy Customers 7

    automotIVe At our automotive stamping plant, our 75- ton critical crane lifts dies at full capacity in order to meet production needs. One morning, our crane operators were hard at work when I witnessed something unsettling: when the crane attempted to make a lift, the load suddenly and unexpectedly drifted back down to the ground. The load had only drifted down about six inches, but we were all shaken by the event. Load drift is extremely serious and potentially very dangerous. We needed to fix this issue immediately.

    We tried to realign the brakes, thinking we could eliminate the problem, but the load drift occurred on and off for six months. We called in several companies to look at the brakes, including the original manufacturer, but no one was able to prevent the loads from slipping. During this time, the cranes experienced emergency breakdowns at least once or twice per week. When a crane broke down, we had to call for an emergency repair, wait for the correct parts and then perform the actual repair. The entire process could last anywhere from four to eight hours.

    We needed to fix this problem immediately, so we called Konecranes. Their technicians determined the factors causing the load drift: the stamping crane used self-adjusting brakes, which were over-adjusting and pushing themselves out of alignment. Though our cranes used variable frequency drives, they were an early model. So when the brakes slipped, they did not have the technology to override the motor to prevent the load drift.

    Konecranes installed new variable frequency drives, which came with advanced safety features. I like the “Brake Slip Detection” feature best: if the brake slips, the inverter drive detects it, keeps the load steady and sounds an alarm. Konecranes also installed new, more reliable brake adjusters. We felt much safer knowing this new equipment minimized the potential for load drift.

    Now, we trust Konecranes to care for all of our cranes. They provide monthly inspections and make sure all our cranes are running properly. Thanks to them, breakdowns at our plant have been decreased by 95% compared to last year.

    a sLIppery sLope a story oF strateGIC upGrades

    Case study: CuSTOMER’S PERSPECTIVE

  • 8 Konecranes • More Happy Customers Konecranes • More Happy Customers 9

    Case studyCase study: CRANE DOCTOR

    At the Automotive Stamping Plant … From the customer’s perspective Have you ever heard the sound of metal scraping against metal? It’s a sound that will make you cringe. We heard that terrible noise at our plant as one of our cranes traveled down the runway—the crane emitted a large, piercing shriek that startled us all. Our safety department locked the crane out of service right away.

    We had chosen the lowest cost bidder to modify the crane for a new runway. Well, I guess we got what we paid for, because when we called the company for help, they bluntly told us the crane was “as good as they can get it” and that the runway was the problem—they even suggested we grease the runway with lubrication sticks to minimize the shrieking. Of course, even with lubrication, the crane did not track properly. To make matters worse, the crane was in the middle of the stamping bay, blocking the other cranes. We needed to get this crane back into service as quickly as possible, so we made an emergency call to Konecranes.

    Meanwhile, at Konecranes … From the Konecranes Branch Manager’s Perspective When Konecranes got the call, every technician had already been assigned to other jobs. So, I called one of our most experienced engineers, a man we nicknamed the “Crane Doctor.” I knew he was on vacation, but I was desperate. Within two hours of the initial call, he informed me he was leaving vacation early to come fix the crane. Out of all the great engineers and technicians I have worked with over the years, I had never before seen one come off vacation to fix a crane.

    His initial inspection showed the crane’s internal components weren’t in their correct positions, a condition that had forced the wheels out of alignment. Thanks to the “Crane Doctor,” the problem was diagnosed and corrected over the weekend, just in time to return the crane to service Monday morning.

    Back at the Stamping Plant … From the customer’s perspective The crane ran smoothly and quietly down the runway

    on Monday morning, and everyone breathed a collective sigh of relief. With the safety department’s blessing, the crane was placed back into service.

    From VaCatIoN to House CaLL

    “We were so thankful the ‘Crane Doctor’ was willing to give up his vacation time to fix our crane. He worked some long and late hours to accommodate our schedule, and his crane alignment expertise was very valuable to us. Our crane is now running as good as ever.”

    Stamping Plant Branch Manager

    Slowed down by daily breakdowns From the customer’s perspective In the busiest production area of our assembly factory, a standard one-ton electric hoist loads a 1,500 pound steel truck frame to a conveyor belt every 54 seconds. This process repeats itself constantly, as workers perform the same action in double-shifts throughout the week. Because the crane was picking at near capacity several times an hour, it was no surpris