Happy Customers - Konecranes...12 Konecranes • More Happy Customers Konecranes • More Happy...

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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.”

VAluESTrust in PeopleWe want to be known for our great people.

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

Sustained ProfitabilityWe 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


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

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

MACHINE TOOl SERVICEPatterson Pump ............................... 37

PETROCHEMICAlEngineering Company ....................... 39Houston, Texas Oil Refinery .............. 40Oil Refinery ...................................... 41

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

ENERgY FROM WASTEEnergy-From-Waste Facility ............... 53

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

INTERMODAl & RAIlCSX Corporation .............................. 61Railroad Yard ................................... 62Locomotive Shop ............................. 63

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


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 sLopea story oF strateGIC upGrades

Case study: CuSTOMER’S PERSPECTIVE


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 surprise when the crane began to breakdown almost daily.

A customized crane built to last From a Konecranes technician’s perspective We found two main problems: the control system and the duty cycle. The hoist used contactor controls, which lacked high-quality speed control options and caused intermittent damage to internal components. In addition, the crane was not designed to withstand the heavy duty cycles it was performing.

Clearly, this standard one-ton crane was worn out and could no longer meet the demands of the factory. So, we customized an extremely durable one-ton CXT crane, built for severe duty, “Class E” service. The crane uses an advanced inverter drive system, which provides smooth, controlled and precise movements. Radio controls allowed crane operators to control the load remotely.

Keeping downtime to a minimum From the customer’s perspective We couldn’t be happier with Konecranes’ work—and with our new crane system, we no longer have to worry about daily breakdowns.

Though the sturdy new crane system was built to last, we wanted to be sure that downtime would not interrupt production. For that very reason, we keep an extra hoist at the facility so we can switch out the hoist any time we need to perform a repair, so that repairs can be completed quickly and accurately.

KoNeCraNes Keeps us truCKING aLoNG


Case study: CuSTOMER’S PERSPECTIVECase study: CuSTOMER’S PERSPECTIVE

Old hoists – a major hindrance At our engine assembly plant, we rely on cranes to position engine components on our assembly line. We were using old air-controlled hoists which were now obsolete. When we started experiencing problems, we couldn’t purchase spare parts because they were no longer available.

Imagine trying to lift and assemble 300 engines per day when your hoist is nearly impossible to use. The hoists drifted without warning and were extremely difficult to adjust. We couldn’t keep up with our production rates with these old hoists, so we decided to scrap them and start fresh.

Konecranes improves lifting with AirBalancer Konecranes came to our facility and demonstrated their dual balancer, and we immediately fell in love. This hoist detects when it has a part, and will remain in the air until the operator moves it. ultimately, the AirBalancer is much easier to control and way more effective than our old hoists.

Since Konecranes installed the new hoists, we haven’t had any issues with breakdowns or unexpected load drift. Downtime at the plant has been drastically reduced, and we are so pleased with our new AirBalancer that we’re planning to install a second one!

KoNeCraNes maKes LIFtING a Breeze

Two of a kindIn the past several years, Konecranes and the maintenance team at our automotive facility have worked in tandem: Konecranes performs annual maintenance, while our in-house team inspects our stamping cranes on a monthly basis. When our maintenance staff is too busy for the monthly inspection—Konecranes handles it, using our checklist, which is based on the Ontario Green Book.

We trust them completely to carry out these inspections—we believe that whatever deficiencies Konecranes finds, our in-house team would have found, too.

The one for usInstead of relying on other crane service providers, we are depending on Konecranes more and more—eventually, they started performing inspections in our body shop, too. Another crane service company had previously handled our inspections in the assembly line area, but when they proved to be unreliable, we granted this area to Konecranes.

With critical inspections from Konecranes, our plant has not had a single production-hindering breakdown in several years—clearly, we were right to trust them! We couldn’t be happier with the unparalleled services they provide at our facility.

a dyNamIC duoKoNeCraNes HeLps us drastICaLLy reduCe BreaKdowNs


Case study: VIDEO

When a leading manufacturing company released a nationwide bid to provide cranes in their production facility in Ohio, five overhead lifting equipment companies gave it their best shot.

After reviewing the proposals, the company decided Konecranes was the most qualified to handle the entire project—from design to installation.

Konecranes determined the best equipment for the building, taking into consideration the building code requirements, current layout and potential architectural challenges. At the production site, Konecranes installed three low-headroom CXT hoists with close end hook approaches, to maximize every inch of available space in the warehouse.

VIDEO: Watch a time lapse video of one of the crane installations here: http://bit.ly/CXTcrane

FINdING tHe Best FIt

maNuFaCturING


Case study: CuSTOMER’S PERSPECTIVECase study: SALESPERSON’S PERSPECTIVE

Meet the new customerLast year, I met with a company that manufactures concrete to discuss Konecranes’ MAINMAN® program and the benefits of preventive maintenance.

As we toured the facility, I asked, “How much did you spend on crane maintenance last year?”

“Well, between the annual inspection, several breakdowns and emergency repairs, we probably spent between $15,000-20,000,” he said. “Those breakdowns really slowed us down.”

“You should try our preventive maintenance plan, MAINMAN®,” I said. “The plan is specifically designed to keep your cranes in better working condition, so breakdowns and emergency repairs won’t be as frequent.”

The concrete company agreed to give MAINMAN® a try for one year, letting Konecranes perform the quarterly and annual inspections and perform every needed repair.

Performance reviewOne year later, the concrete company has not had a single breakdown. In fact, no production time was lost at all, because each repair was performed during scheduled downtime.

By using MAINMAN®, the company spent substantially less on maintenance. In fact, they even saved enough money to buy a brand new hoist and still remain within budget for the year.

LeaVING dowNtIme IN tHe dust

The Day OSHA came knockingIt was not a pleasant day at our plant: we had an unexpected OSHA audit and were caught without proper documentation for our overhead crane inspections. To be honest, we didn’t even know we needed these documents before the audit!

In addition to the fine, now we were required to have a follow-up audit. Needless to say, our cranes needed to be in tip-top shape (with all the right documentations) before the follow-up visit.

Konecranes to the rescue A colleague recommended Konecranes, a local crane service dealer, and I decided to give them a shot. The Konecranes inspector made recommendations based on the specific inspections we needed. To make sure we were thoroughly prepared for the follow-up audit, he also trained our employees on OSHA requirements for crane operators. Lastly, Konecranes repaired our cranes based on the inspection results.

Ready for the reckoning We gave Konecranes a tight, two week deadline to make the repair. They understood the urgency of the situation and made this project a top priority, using as many technicians as possible and rearranging welding and other schedules to accommodate us. The repair took only one week to complete and the drum was back in service in less than two weeks—what a relief!

INspeCted to meet osHa requIremeNts, aNd BeyoNd!


Case studyCase study

At the plant...Lurking below the surface of the gear case, glittering specks of metal rested on a thick sludge of oil inside the gear case. The gear case had been neglected for years while another company serviced the cranes. With damage this bad, the crane could have been moments away from catastrophic failure...

Things were about to change: the company, which manufactured automobile interior mechanisms, released a bid for a new crane service provider, after a Konecranes salesperson explained the benefits of thorough MAINMAN® inspections.

A shocking discovery During the initial MAINMAN® inspection for the plant, a Konecranes inspector peeled open the gear case cover to find the filthy state of the oil inside. When he saw glittering specks of metal, he knew that pieces of the gear teeth were disintegrating into the oil. Quickly, he alerted the plant safety manager and locked the crane out of service.

The plant had been extremely close to disaster. If the gears had meshed improperly, the crane could have dropped a steel die. Imagine the worst—the die plummeting from the crane, colliding into the machinery or workers below, smashing into other dies and creating thick cracks on the concrete floor.

Konecranes repaired the gears and explained the importance of regular gear case inspections—the plant was extremely grateful. Now, Konecranes replaces the oil and performs open gear case inspections at the facility regularly. With MAINMAN® inspections, Konecranes hopes to help reduce the risk of close-calls like this in the future.

How a maINmaN® INspeCtIoN preVeNted aN ImpeNdING CatastropHe

Room to grow With customer demand on the rise, K.K. Tool needed to add several CNC machines to keep up. The machines were squeezed into the existing shop, wherever there was room. As demand continued to increase, it soon became clear more space was needed to handle the growing business.

K.K. Tool expanded their facility—adding a 4,000 foot addition for the eight new machines. The company also began exploring lifting options to streamline workflow around the CNC machines.

Konecranes’ space-saving craneAfter consulting with several companies, K.K. Tool contacted Konecranes, who proposed a unique solution—an XN trolley and hoist on a light-track enclosed rail system. Suspended from the ceiling, one crane could service all eight milling machines, while keeping the floor area free for forklifts to maneuver.

Konecranes XN crane has a distinct feature – an articulated bridge which allows one end to move ahead of or behind the other, by as much as three feet. This ergonomic feature significantly reduces the amount of effort needed to move the crane along the track and allows small adjustments to be made without moving the entire bridge.

K.K. Tool has been using the XN system for about six months now, and is seeing the productivity benefits. Due to the success of this crane system, the company is exploring the possibility of adding another XN hoist to the existing track.

rIGHt oN traCKa suCCessFuL system to ImproVe produCtIVIty Company Information: K.K. Tool Company is a family-owned enterprise in Springfield, Ohio. Competing globally, the company creates stamping dies for the heavy equipment industry and production machining products.

“The only way we can compete effectively is to work with machinery that helps us to make a product faster. So, we have to work smart by investing not only in employees and training, but also by investing in equipment that allows us to produce products in a more timely manner.” ”

Kris KoehlerK.K. Tool


Hidden hazardImagine trusting your crane service provider to inspect your overhead lifting equipment—only to find out they were not telling you about comprehensive inspections that could be critical to the safety of your personnel.

That is what happened to Toyota-Lift of Minnesota, who used another crane service provider for nearly 15 years without being informed of the safety benefits involved with performing inspections on internal components. “We had not been told about these inspections, despite 14 annual inspections performed by companies other than Konecranes,” said Kyle Thill, Director of Service at Toyota-Lift of Minnesota.

The standard inspections performed at Toyota-Lift of Minnesota relied mostly on visual observations and measurements. However, not all defects can be seen with the naked eye.

Toyota-Lift found Konecranes after a few failed attempts to contact their vendor to schedule an inspection. “Their failure to do so for approximately two weeks made us look for alternative solutions, and we discovered Konecranes,” said Thill.

Critical InspectionKonecranes worked with Toyota-Lift to develop a customized inspection plan for the 5-ton bridge crane. Based on the equipment’s use, environment and age of the hoist, Konecranes advised Toyota-Lift to perform internal inspections on the gear case, load block and hoist coupling.

The inspections revealed that the needle bearing in the gear case had started to fail. Without this inspection, the tear could have led to a sudden and catastrophic failure. Konecranes is now Toyota-Lift of Minnesota’s preferred vendor for crane inspections and maintenance.

Case study: CuSTOMER’S PERSPECTIVECase study

KoNeCraNes reduCes rIsK wItH Gear Case INspeCtIoNCompany Information: Established in 1978, Toyota Lift of Minnesota currently offers a full line of high-quality lift trucks, aerial equipment, personnel and burden carriers as well as warehouse and material handling systems.

“Now we have the comfort of knowing this piece of equipment is operating safely.”

Kyle ThillDirector of Service

New facility needs a brand new crane Last December, our company needed a one-ton workstation crane for the new facility we were building. The project was complex for a number of reasons: our facility utilized boilers for heat treating, which required piping on the walls. So, the workstation needed to work around the pipes. Our building was nearly finished, so we needed to get a quote as soon as possible.

Konecranes proves to be the right choiceWe gathered quotes from several crane companies, but we still weren’t satisfied. That’s when our production supervisor suggested that we call Konecranes, since they had been performing our overhead crane inspections for the past three years. They prepared a quote for the project in just one day and proved to be the most cost-effective option when we considered total cost of ownership.

Konecranes delivered the one-ton XM workstation with two half-ton bridges in just three weeks. With the chain pendants and the push/pull bridges and trolleys, we can move products in and out of our heat treatment system with ease. Better yet, this freestanding system doesn’t interfere with the piping. Overall, this new process is much faster, and the lightweight crane proves to be much easier on the workers.

New BuILdING? New CraNe? No proBLem!



MAINMAN® catches major problemWhen we first tried Konecranes MAINMAN® inspections, we noticed a vast difference. Instead of a simple checklist for “Compliant” or “Non-Compliant” items, the MAINMAN inspection involved details, graphs and a plan of action. Not only that, the inspections included components our checklists missed – namely, our trolley gauges, which needed to be re-adjusted. We are glad these problems were spotted so the proper adjustments could be made: this damage could have led to derailment, skewing or a load drop.

Reaching far beyond inspectionsAfter Konecranes solved this problem for us, we had another major need in our valve-testing area. We had only one jib to cover two bays. Our forklift trucks would attempt to attach the valves to the jib, but the grated floors prevented the trucks from moving all the way into the testing space. Then, our workers needed to scoot the valves the rest of the way with manual push pallets. Clearly, this situation was not efficient or safe.

Thankfully, Konecranes custom-built a solution: Workstation Lifting System jib cranes with a bridge in between them. Because this system was mounted directly to the wall, it did not require any floor space and spanned much more floor space than an additional jib could have. Now, our XN chain hoist can travel through the entire testing area, which lets us transport valves twice as fast as our original situation. Thanks to Konecranes, our plant is well-maintained and running smoothly!

KoNeCraNes GIVes our pLaNt a muCH-Needed maKeoVerCompany Information: Piper Valve Systems produces compact high pressure valves and manifold system components for the oil and gas industry.

limited mobility leads to limited productivity At our facility, we rely on our overhead cranes to lift molds into a plastic injection molding machine. Our original system was outdated and not very productive: the machine was misaligned and couldn’t move left to right. This meant that our employees had to push the crane by hand, and force the molds into place. Not only was this extremely difficult, but it also slowed things down significantly at the plant. On top of that, the cranes used pendant controls. Since the cords were not very long, employees often had to stand on the machine to operate it.

It was time for a change—we needed a new system that would eliminate these mobility issues and increase our efficiency.

Konecranes sets plant in motion with new crane system Konecranes had the perfect solution: two 175’ long, two-ton capacity freestanding workstation cranes with radio controls. Now, we no longer have to worry about pushing the cranes by hand. Instead, the new workstation cranes lift and load our molds with speed and precision. The radio controls allow our operators to maintain a comfortable distance from the cranes, since they are no longer limited by cords.

Overall, we’re very pleased with our new cranes. Konecranes technicians were able to install the new system without interrupting production. Now, we feel confident that our plant can run efficiently!

KoNeCraNes Keeps us moVING wItH worKstatIoN CraNes


Case studyCase study: CuSTOMER’S PERSPECTIVE

looking for a brand-new crane At our new facility in Horsehead, N.Y., we needed a crane as soon as possible to aid us in routine maintenance of our Coil Tubing Services truck and trailer fleet. This crane also needed to be capable of lifting the devices we produce—some of which can weigh up to 4,000 pounds. Because our business is constantly growing and expanding, we needed to find a crane company who could not only provide us with reliable equipment, but also with fast, excellent service.

Konecranes proves to be the perfect fit LeChase Construction Services recommended that we call Konecranes—they had purchased cranes from Konecranes in the past and assured us they were reliable. After careful consideration, we decided to go with Konecranes for five of the six overhead cranes in our facility.

Konecranes installed a 5-ton single girder top-running crane for us. With inverters on the bridge and trolley, our cranes run smoothly. The two-speed hoists with remote controls give us the control we need to operate the crane and lift with ease. We were impressed with their outstanding service and fast follow-up. In fact, now Konecranes is servicing all of the cranes in our plant. Clearly, we made the right choice.

tHe perFeCt ComBINatIoN oF equIpmeNt aNd serVICe Company Information: Schlumberger Technology Corporation is the world’s leading oilfield services company supplying technology, information solutions and integrated project management that optimize reservoir performance for customers working in the oil and gas industry.

Before…Back in the day, an automated material handling facility used two 12-foot jib cranes in its manufacturing process–producing components for conveyor systems. With the long, 12-foot jib cranes in the middle of the runway, it became difficult to load and unload their product.

After…Konecranes replaced both jib cranes with two overhead cranes—one on a 50’ runway and one on a 100’ runway system. Now, they have the entire floor space to load and unload their product.

GoING tHe dIstaNCe



An inefficient systemAt our component manufacturing facility, we were in the midst of putting in a new process, a hand peening booth, where workers could chip away at the metal surfaces of the 400-pound tractor-trailer axles we manufacture. We had a small handful of employees working on this process, which involved moving the axles using a combination of manual labor, forklift trucks and an overhead crane with a chain host.

We needed a new crane system that would allow us to lift and place the axles faster.

Konecranes sets plant in motion with new crane system Konecranes installed two free-standing XM Workstation cranes in order to eliminate the issues we were having. About halfway through the installation, the Konecranes team and I came to the realization that this system wasn’t going to work for us. We had hired more employees, so we needed more workstations for them to use. Konecranes immediately began to help us re-strategize: in order to be more productive, we needed to be able to have more employees lifting and working on the axles at one time. Konecranes suggested that we add more bridges, which would give us more flexibility and add additional workstations for our employees to use.

The perfect fixRather than having us purchase an entirely new system, Konecranes engineers used all the existing components of the XM Workstation cranes to develop an entirely new system, which saved us a good bit of money. Now, instead of three bridge workstations, we have 10, and we couldn’t be happier with our new system!

KoNeCraNes redesIGNs CraNe system to suIt our Needs

Time for a changeWhen our original crane service provider was acquired by Konecranes several years ago, we were required to change our maintenance plan. Konecranes worked with us extensively to ensure that our transition went as smoothly as possible, especially since we were already accustomed to our regular maintenance plan. As we worked with Konecranes on a new contract, they took extra care to make sure their employees were well-equipped to take care of our facility—each employee underwent specialized training so they would know our safety policies and operating procedures.

Konecranes MAINMAN proves to be the best I was a little reluctant to try Konecranes’ MAINMAN inspection program, especially since I had been satisfied with our previous inspection contract. As soon as we started working with Konecranes, I immediately fell in love — I was impressed by how convenient it was to plan repairs in advance and check the progress of inspections and repairs online!

Konecranes continues to work closely with us to make sure all our equipment is kept in top condition. We were so impressed with Konecranes’ ability to handle our inspections that we started to trust them with larger projects as well — now, they’re working on two full-scale engineering jobs at our refinery.

maKING tHe swItCH: KoNeCraNes eases tHe traNsItIoN to maINmaN®


Case study: SALESPERSON’S PERSPECTIVE

A difficult mission A chemical plant located in Texas needed to increase the stability of their cranes by upgrading to inverter drives. The air-controlled cranes regularly performed high lifts at nearly full capacity. The heavy duty cycle, combined with the hot environment of Texas, caused the mechanical load brake to overheat frequently.

Inverter drives would eliminate the need for a mechanical load brake and would ease the plant’s problems. There was just one catch—due to the high levels of chemicals in the plant, the new control system would need to be specifically engineered to withstand explosive environments.

Konecranes engineers face the challenge head-on While other competitors shied away from the project, Konecranes had both the resources and the expertise to develop a system to allow inverters to run in the highly-reactive environment.

With top-of-the-line equipment, Konecranes engineered explosion-proof panels designed to prevent chemicals from entering the control box. For added protection, the engineers developed a system to pump a constant flow of pressurized air into the control box. The pressurized air was also designed to protect the controls from heat damage. Now, the plant can reap the benefits of inverter drives in an environment where the drives normally could not exist.

mIssIoN: ImpossIBLe? KoNeCraNes perForms adVaNCed moderNIzatIoN IN Hazardous eNVIroNmeNt

Case study

Monthly breakdowns reveal the need for a more proactive maintenance planA brewery in Ohio utilizes hundreds of overhead lifting equipment throughout their facility. Their crane maintenance team performed regular inspections as required, but did not proactively seek to reduce breakdowns. In a particularly high volume area, a few of the cranes regularly broke down on a monthly basis.

They needed to find a way to reduce these monthly breakdowns in order to increase productivity.

Working to prolong crane lifeKonecranes performed an in-depth inspection on each crane, searching for defects and deficiencies. Experienced technicians followed the Konecranes MAINMAN® process, evaluating the condition of every crane in the building and ranking the cranes based on safety and production needs. A customized maintenance plan was created based on the condition of the equipment and the production needs.

The brewery made each repair in a timely manner, with hopes to reduce downtime due to breakdowns. Technicians replaced brake pads, which had been wearing thin. Without the thorough brake inspection, the worn brakes could have led to a load failure. Any chain hoists with defects, rust or corrosion were replaced with new Konecranes XN hoists.

With every item thoroughly inspected and repaired, breakdowns and repair costs have been drastically reduced.

proaCtIVe Care reduCes BreaKdowNs By 99%



My aching back I’ve been working at a bottling factory in Columbus, Ohio, for years. As bottles spin across the conveyor belt, a machine wraps the labels around them. In the past, when the labels needed to be replaced, we had to lift a 75 pound block of labels and feed it into the machine. I left work every day feeling exhausted and sore. I started to dread having to lift those labels because it strained my back so much. I knew other employees felt the same way, so I finally decided to take action.

A better way to lift labels The factory manager agreed when I told him that something needed to be done, so he called Konecranes and started discussing some possibilities. After reviewing a lot of different lifting devices, he decided that an XM freestanding aluminum system with an AirBalancer hoist was the best choice. Konecranes installed the entire crane system in only two days, and I couldn’t wait to start using it.

Konecranes AirBalancer provides much needed reliefThe AirBalancer is great for so many reasons— first, the custom-built runway covers the length of all three of our labeling stations, so everyone can use the hoist. Second, the AirBalancer instantly senses and counteracts the weight of the label blocks, so the load feels practically weightless to me! And then, with just a flip of a switch, the air hoist turns into a manipulator, so I can move and place the labeling blocks without straining my back. So now, lifting those labels is no problem!

aIrBaLaNCer’s Got my BaCK

Case study

Konecranes provides comprehensive, hands-on training The Konecranes Training Institute’s relationship with this offshore drilling components manufacturer began in 2008. Several of their facilities throughout the country have received on-site, Train-the-Trainer instruction from the Institute. Crane operators with varying levels of experience, from as few as two years to as many as 25, have participated in the training program. Instructors of the Institute put knowledge in layman’s terms and perform hands-on training to show employees proper rigging techniques, load ratings and inspections on their equipment.

The training continues Today, the training relationship continues to evolve and now includes training for Rigging, Mobile Crane Operator and Hand Signal Training. Konecranes provided eight courses for them in 2011 and continues to offer classes in 2012. Jim Lang, General Manager for the Konecranes Training Institute said, “In 2011, we trained over 80 of their personnel in our customized Train-the-Trainer program.”

eNHaNCING saFety wItH CraNe operator traINING

“Even employees with more than 15 years’ experience said they came away from the course having learned something new.”

Regional Manager



Tired of heavy lifting At our plant, we needed a new crane to help us perform machining and tooling tasks and load products into fabrication machines. We received a new machine tool, and desperately needed a new crane for that workstation area.

light as airWhen Konecranes came to demonstrate AirBalancer, an air-controlled hoist and manipulator on an extremely lightweight, freestanding aluminum system, we all immediately fell in love with it. The hoist made items feel practically weightless!

Konecranes installed a 500-pound capacity aluminum XA crane with a 100-pound capacity AirBalancer in only a few days. The freestanding crane system improved our whole situation in general. Because it spans the entire workstation area, we are able to move the hoist exactly where we need it. We can even add more units as we grow. With AirBalancer, employees can perform all machining and tooling tasks with ease.

aIrBaLaNCer aLLows empLoyees to LIFt wItH ease


Then...At our pound cake factory, we were stuck with an obsolete, out-of-date overhead crane. The crane was crucial because it was used to perform maintenance on our conveyor belt. But because the crane was so old, we were constantly dealing with breakdowns and the crane needed to be repaired frequently. Whenever the crane broke down, we lost hours of production time.

Several of our other facilities were using Konecranes hoists, and were very enthusiastic about these cranes. So, we decided to follow suit.

Now...After touring our facility, Konecranes recommended a 1-ton capacity XN hoist, with a food-grade hoist so it would not contaminate the product. As soon as they installed our new crane, we were impressed!

Now, Konecranes provides yearly inspections and preventive maintenance to ensure that the new crane doesn’t break down. With fewer breakdowns, we can focus on our pound cake instead of worrying about expensive emergency repairs!

wItH KoNeCraNes, reduCING BreaKdowNs Is a pIeCe oF CaKe


Case study

Company claims brake “obsolete”The overhead crane at an electrical components factory broke down after a bridge brake failed. The crane was an essential part of the manufacturing process, as workers used it to transport steel to fabrication machines. When the facility asked their crane service provider to replace the part, the service provider claimed the part was obsolete. There seemed to be only two options: replace the crane entirely or custom manufacture a new part. Both options would be expensive and could require months of downtime.

Konecranes finds correct part The facility contacted Konecranes for a second opinion before moving forward with a new crane. Konecranes assured them the problem could be easily solved, and the part needed was not actually obsolete. Konecranes technicians gathered information from the brake plates and used this information to determine the correct brake style for the crane.

Part ordered and installed in two weeksKonecranes technicians set the brake according to OEM requirements. After performing an operational test, the crane was placed back into service—only two weeks after the breakdown. With the quick brake installation, Konecranes saved the facility thousands of dollars in remanufactured parts and weeks of unnecessary downtime.

quICK tHINKING saVes Customer weeKs oF dowNtIme

Case study

tHe KoNeCraNes smV LIFt truCK KNoCKs out tHe CompetItIoNBetter, Faster, stroNGer: LIFt truCKsCompany Information: Toyota Material Handling is Northern California’s leading full service Material Handling dealer of everything from lift trucks to utility vehicles.

It was time for us at Toyota Material Handling Northern California to make a tough decision: Which lift truck should we choose for our customers? We had three rounds to decide, based on Maintenance, Strength and Cost.

Stepping into the ring, the SMV Konecranes lift truck shows tremendous reliability, with a load sensing hydraulic system that only needs to be serviced every 4,000 hours. What a tough number to beat!

Here comes the rest of the competition, with service required every 1-2,000 hours.

THE FIRST ROuND gOES TO … Konecranes SMV

But lift trucks need more than just low maintenance costs; they need to be tough. Which lift truck is stronger, tougher and more durable than the rest?

In a test of strength, the Konecranes SMV is the clear winner. On average, Konecranes’ box section frame is twice as strong as the channel “C” frame the competition uses.

THE SECOND ROuND gOES TO … Konecranes SMV

The crowd is anxious for the final, and possibly most important, round. Which truck is the most cost-effective? Knocking out the competition, the Konecranes Lift Truck shows off an astonishingly reasonable price tag!

AND THE WINNER IS … Konecranes SMV!

“At Toyota Material Handling of Northern California, we know a champion product when we see one. That’s why we chose to supply the Konecranes SMV Lift Truck to our customers.”


Case study: THEN AND NOW

Then…The odds were against Tencate Advanced Armor. They desperately wanted to bid on a multi-million dollar order to create bulletproof lining for vehicles, and they had an extremely short time frame to prove themselves. Relying on forklift trucks, they were only producing 50 armored linings per day—a mere third of what the new order required. If they were going to win this order, they needed to triple their production rate, and they needed to do it immediately.

With time running out and the odds stacked against them, Tencate called Konecranes. Working as quickly as they could, Konecranes determined several options. Given the time constraints, it would be impossible to install overhead cranes—that would take weeks. There had to be another solution…

That’s when it hit them: freestanding XM cranes with vacuum lifter attachments. They were installed in a matter of days—no time was wasted. Four days later, Tencate had a brand new system that allowed them to change the aluminum dies with speed and precision.

Now…So, did their plan work? Were they able to succeed? Yes! Because the upgrade was completed so quickly, Tencate won the order by proving that they had what it took to meet the production requirements. Now, they produce a record-breaking 200 aluminum molds in one day—above and beyond any amount they could have produced when they were using their forklift trucks.

HIttING tHe tarGetKoNeCraNes HeLps teNCate wIN muLtI-mILLIoN doLLar BId Company Information: Tencate Advanced Armor manufactures armor lining for North American military vehicles. The bullet-proof armor fabric protects military vehicles from bullets, fire and improvised explosive devices (IEDs).

Wanted: sleek, top-of-the-line cranes Christie was building a new showroom for its high-end projector systems so clients could preview their installations. They needed new cranes that could assemble their rear-view projectors with precision and care, especially since these components could cost up to a million dollars. Christie not only wanted a reliable system, but also wanted cranes that would be visually compatible with their sleek, modern equipment.

Konecranes installs brand new XN system Konecranes provided exactly what Christie needed: a brand new XN enclosed track system. This system suited Christie’s needs for a number of reasons: first, the two workstation cranes were highly ergonomic, with variable speed drives for bridge and trolley motions. Second, the cranes were capable of supporting centers up to 30 feet along the runway, which reduced the need for additional support. Third, the system was easy to operate and moved with precision. Finally, the entire system had a clean, uncluttered look, so aesthetically, it was an easy fit into Christie’s showroom.

Reliable cranes a big hitOverall, Christie was pleased with their new installation. Luis Laino, manufacturing engineer at Christie’s showroom said, “I can lift a $50,000 component, and if it falls, it will fall all over a project that someone has paid up to a million dollars for. [These cranes] are reliable—that is my favorite feature! Over the last year and half, absolutely nothing has happened to them or the loads they’ve handled.”

more tHaN Just a pretty CraNereLIaBILIty aNd preCIsIoN proteCt CHrIstIe’s proJeCtors Company Information: Christie is a global visual technologies company offering solutions for business, and entertainment. Audiences have been awestruck by their over-the-top projected virtual reality events at venues such as the 2010 Vancouver Olympics.

Case study


Case study

maCHINe tooL serVICe

KoNeCraNes maCHINe tooL serVICe proVIdes deCades oF exCeLLeNt serVICe

A facility filled with critical machine tools Patterson Pump, a manufacturer of some of the world’s largest water pumps, relies primarily on large sophisticated machine tools to manufacture a variety of their products. These machine tools are in production 24/7 and are the lifeline of their business. With machine tool downtime potentially costing the plant anywhere between $200-600 an hour, it is essential these machine tools are kept in excellent condition.

Machine Tool Service keeps facility running in peak condition The experts at Konecranes Machine Tool Service have been supporting Patterson Pump for over 20 years – prior to October 2009 operating as Machine Tool Solutions unlimited. As Konecranes Machine Tool Service, they continue to provide the same quality rebuilding, retrofitting and preventive maintenance services today.

When a flash flood left every machine tool in their facility damaged, Patterson Pump contacted Konecranes Machine Tool Service to handle the recovery process. under the direction of Harold Schoch, Machine Tool Services Director of Sales, numerous Machine Tool Service specialists were deployed, along with several Konecranes crane specialists, to support the recovery.

Working in concert with Patterson Pump employees, Konecranes machine tool and crane specialists repaired all of the machine tools and placed them back into operation in a timely and efficient manner. This prompt workmanship resulted in substantial savings to Patterson Pump.

Beyond Machine ToolsPatterson Pump was recently looking to purchase two 75-ton overhead bridge cranes. Due to the excellent service Konecranes Machine Tool Services provided to the facility, Patterson Pump decided to purchase this new equipment from Konecranes.

Company Information: Patterson Pump is a world leader in fire protection and municipal pumps, using the latest in computer aided pump design to offer customers state-of-the-art products.


Case study: QuICK FIX

petroCHemICaL

How a sImpLe moderNIzatIoN added muLtIpLe produCtIoN Hours to tHe day

Just out of reach Our engineering company used to deliver tanks from the paint shop directly to the loading dock. When we changed our manufacturing process and stopped painting these tanks, we had to change the location of our loading dock. This change should have been seamless, yet it turned out to be a major problem. Our overhead crane had a limitation setting built to suit our prior needs. This feature forced the crane to stop at a certain location along the runway—which now happened to be a few feet short of the loading dock. We tried to override this setting to allow the crane to travel the last part of the runway to the loading dock, but with the crane’s limited control system, it simply was not possible.

For nearly four months, we compensated–using lift trucks to carry the load the last four feet. This maxed out the lift trucks and wasted valuable time; after lowering the load from the crane, the rigging was removed and then the load was strapped to the lift trucks for the remainder of the journey. The system also presented a potential safety hazard. As manual labor increased, injury potential also increased.

Konecranes’ quick fix For many years, we had been dissatisfied with our crane service provider, which is why we decided to contact Konecranes.

Konecranes modernization engineers quickly relocated the travel zone limit to give the crane access to the newly-required loading area. This modernization saved 10 minutes per load. With an average of 20 loads per day, this quick fix added over three hours to our production day!

Picture this: An overhead crane lifts an oil refinery tank, and it floats through the factory like a massive white cylinder in the air. It’s quite a sight to see—that is, until the crane abruptly stops along the runway—just four feet before reaching the loading dock.


Case studyCase study: SALESPERSON’S PERSPECTIVE

An oil refinery outside of Houston, Texas has over 600 pieces of equipment, all of which need to be inspected monthly. I send in my best, most qualified technicians to work on-site to help keep the plant 100% OSHA compliant. With thorough inspections completed every month, the repairs are done as quickly as possible. However, our relationship extends far beyond these detailed monthly inspections.

Sometimes the refinery asks us for help with more specialized projects. For example, when hurricane winds were coming, they were worried they did not have a great way to lock down their equipment. So, we helped design wind locks for them. These wind anchors, which are designed to lock outdoor cranes into place during severe weather, helped the refinery keep their equipment safe during the harsh storm.

We’ve been working with this refinery since 1995, and it’s clear that our relationship has been built to last.

more tHaN Just FaIr weatHer FrIeNds

Cracked drum requires immediate attention When employees at this oil refinery spotted cracks on the drum of their heavy duty coker crane, they knew they needed to act quickly. Results could be tragic. If the crane was out of service too long and unable to produce petroleum for an extended period of time, the entire refinery could be forced to shut down.

Konecranes sent an experienced modernization engineer to assess the situation. using his years of experience, he worked quickly to diagnose the drum. He soon determined a failure had occurred between the gear and the drum. Because the shaft was hollow, it did not provide the stability required for the crane—there was too much pressure on the shaft as it entered the drum.

Modernization to save the drumThe engineer made the necessary repairs at Crane Pro Parts, Konecranes’ parts organization. With great precision and care, he increased the diameter inside the hoist drum and redesigned the shaft – making it completely solid. The redesigned shaft had the necessary strength to prolong the life of this coker crane.

KoNeCraNes eNHaNCes tHe LIFe oF a CrItICaL CoKer CraNe


power

Case study: DuAL PERSPECTIVES

How KoNeCraNes HeLped Keep tHe Los aNGeLes CIty LIGHts oNCompany Information: The Los Angeles Department of Water and Power provides reliable electric service and safe, affordable water to the city’s 3.8 million residents and businesses.

The power for the city of Los Angeles comes from a most unusual, yet scenic location. The Castaic Power Plant is cut into the mountains surrounding the Castaic Lake. The plant passes water from local reservoirs in order to generate hydroelectric power for the city.

A minuscule window of opportunity Written from the Customer’s Perspective Last spring, our generator was scheduled for a complete overhaul in only a few months, but we had a major problem. When our generator needs maintenance, two massive bridge cranes work in tandem to lift and carry it over 500 feet of railway. With the city of Los Angeles depending on the generator for a portion of their power supply, our window of opportunity for repairs is very small. However, our cranes were not ready to lift the generator. The rails were outside of tolerance requirements, which had caused excessive wheel wear.

Our goal was to replace all 500 feet of railway, along with 32 bogey end truck wheels in two months—otherwise, we were going to miss the deadline for upgrading our generator.

Meticulous planning pays offWritten from the Konecranes On-Site Manager’s Perspective My priority was to make sure this wheel assembly and rail replacement was carried out safely and efficiently. Each day, I sat down with the branch and went over the plan for that day, working to avoid potential safety issues. Everything needed to be scheduled to the last detail because this was a logistically difficult project. We devised a system to work on the railway and the wheels simultaneously. Because the wheels had to be driven two hours to a Konecranes service branch in order to be repaired, we even took traffic time into consideration to make sure everything went smoothly.

Ahead of schedule, breathing a sigh of relief Written from the Customer’s Perspective Thanks to Konecranes’ efficient work schedule, the replacements were completed two full weeks ahead of schedule. I was so pleased with their extensive planning, hard work and dedication to the project. Konecranes went above and beyond to ensure we would be able to upgrade our generator.


Case study: BRANCH MANAGER’S PERSPECTIVE

An unusual request One day, to our surprise, a competitor called our local office requesting our technician’s help. A hydroelectric plant was experiencing load brake issues with one of their cranes. The plant needed to repair the crane in time for a scheduled turbine change. By the time the competitor called us, the crane had been out of commission for several days, and they were unsure of how to solve the problem.

Speedy repair leads to new relationship Though this was an unusual situation, Konecranes decided to step in and help. Our modernization representative worked in conjunction with two of our most experienced technicians to repair the crane. In just a couple of days, the crane was up and running—just in time for the turbine change.

After our repair, the plant was no longer interested in working with our competitor. Because many of their cranes are decades old, we started to work with the facility to upgrade the cranes. They awarded Konecranes with an annual MAINMAN® Inspection contract not only with that specific plant, but with all six plants in the area.

KoNeCraNes Comes tHrouGH IN a BINd


Worn down components pose problems During a Konecranes MAINMAN® inspection of a hydropower plant’s 80-ton Turbine Room crane, we came across a major problem: the upper and lower sheave blocks showed excessive wear, which could, if left unattended, lead to a breakdown. Though the crane was used infrequently, it was essential to the facility, as they used it to lift their enormous turbines. With a scheduled turbine replacement on the horizon for AEP, this crane needed to be in top condition. After speaking with one of our modernization engineers, we advised AEP that they replace the sheaves in the upper sheave nest and lower block assembly, and upgrade from bronze brushing to a newer, roller bearing for the new sheaves. They asked us to do the upgrades because of our expertise, as well as our willingness to adapt to their safety regulations.

An essential repair During the inspection, we also discovered a second problem. The festoon had been installed in the wrong location by another crane company during a previous repair. We quickly adapted the scope of the project to include moving this festoon into the proper place. The turbine room crane was repaired and returned to service immediately following the work. Even with the last minute festoon relocation, we were able to complete the project in time for their scheduled turbine replacement.

Since the repair, the crane has been performing in top condition. In the future, our goal is to help the plant reduce the need for extreme and costly repairs by implementing a preventive maintenance plan.

KoNeCraNes demoNstrates tHe ImportaNCe oF proaCtIVe Care


Case study

Out of time, out of options At the Los Angeles Department of Water and Power (LADWP), two massive 375-ton cranes lie in wait. Though used infrequently, the two overhead lifting devices are essential. Working in tandem, the plant depends on these cranes to lift hydro turbines out of the building for scheduled maintenance.

LADWP had a small window of opportunity to perform maintenance work on the turbines, and the wheels had worn too thin to safely perform the lift.

Working together for faster speedLADWP began searching for a provider to keep the maintenance work on schedule. Konecranes won the competitive bid to design, manufacture and install wheels. To meet the deadline, Konecranes depended on the strong partnership between its service and parts departments.

To determine the specific needs of LADWP, a product manager from Konecranes parts department, Crane Pro Parts, and the local service branch traveled to LADWP’s site. While at the site, Konecranes analyzed the equipment, took preliminary measurements and discussed the customer’s expectations. The Crane Pro Parts product manager also made recommendations to upgrade the raw material specifications, test certification and performance requirements and simultaneously replace the axles to prevent damage during removal and/or installation.

The Konecranes parts manufacturing facility pushed the project forward quickly, delivering the two sets of 16 wheel assemblies ahead of schedule. The Konecranes service team replaced all 32 wheel assemblies, allowing LADWP to complete the scheduled maintenance on time.

Konecranes service and parts departments were able to partner together to help the end user:

• understand the scope of the challenge• Recommend a solution • Deliver the recommended solution – ahead of schedule

By partnering together, the two departments were able to demonstrate the overall capabilities of Konecranes.

No tIme? No proBLem!CraNe pro parts deLIVers wHeeLs IN a FLasHCompany Information: The Los Angeles Department of Water and Power provides reliable electric service and safe, affordable water to the city’s 3.8 million residents and businesses.


An impressive featThe moment of truth had arrived: 75 invited guests—including business partners, elected officials and economic development leaders — stood alongside our 100 employees inside our massive assembly plant. As the crane lifted the cover onto the wind turbine, the audience applauded enthusiastically. This was a remarkable achievement for Acciona and another major step toward renewable energy solutions.

The right crane for the job At our brand new facility in Iowa, we needed a crane that could perform a very specific, extremely important task. We needed a crane that could, when the time was right, lift the 3,000-pound cover off our 130-ton wind turbine and then transport the turbines out of the facility for delivery. This AW3000 wind turbine, a new, more powerful and efficient wind turbine, was the first of its kind to be built in North America. We needed a reliable crane to do the job. That’s why we chose Konecranes to provide a 190-ton overhead crane for our plant.

Without Konecranes, none of this would have been possible. Their reliable equipment allowed us not only to assemble our wind turbine, but to demonstrate a bright future for wind technology.

a BrIGHter Future wItH KoNeCraNes’ HeLp Company Information: ACCIONA, a global leader in alternative energy solutions, has been pioneering renewable energy for over 20 years and is active in all of the five major renewable-energy solutions. For more information about ACCIONA’s AW3000 wind turbine, visit www.aw3000.com.



Controls in need of repair When this coal-burning power plant was faced with a major problem, they immediately called us. Their original Static Stepless crane controls had become unreliable and needed to be repaired as soon as possible. Because we had been performing inspection repairs at their facility for several years, they asked us to quote the project—and we were awarded the bid over three direct competitors based on our project proposal and ability to complete the project on time.

A successful upgrade Because very few companies know how to repair and maintain Static Stepless controls, we knew this project was going to be a challenge. We sent one of our most skilled Konecranes technicians to upgrade the crane to new inverter drives as well as remote controls—but he didn’t stop there. To improve the crane’s performance, he replaced all gear case and running gear bearings. Without his dedication and technical know-how, we never would’ve been able to complete the project on time. Since the upgrade, the power plant has had very limited breakdowns and has a complete set of spare parts. They were so pleased with our cost-saving upgrade, they asked us to perform the same upgrade on their other turbine crane.

KoNeCraNes wows FaCILIty wItH CraNe upGrade

“Konecranes always provides excellent service—and like always, they impressed us with this crane upgrade. Our crane runs better than ever and we are thrilled that they’re working on our other crane!”

Plant Manager

Case study: EXTREME CRANE MAKEOVER

A serious undertakingWritten from the customer’s perspectiveIt was a critical time or us at the plant. We were in a panic because the Department of Energy had just posed more stringent requirements for overhead cranes, which meant that our 50-year-old crane wasn’t compliant anymore. But that wasn’t even the worst of it! We needed to upgrade our crane immediately, which was going to be challenging for several reasons: first, the crane was unbalanced and located in a very tight space, so moving it was going to be tricky. Second, and most importantly, the crane was located in a contamination area—which meant this could be a hazardous process. We needed to find a company who could face these challenges head on and modernize our crane quickly, but even more importantly, we wanted a company who could do this with zero safety incidents.

Taking charge of the transformationWritten from a Konecranes technician’s perspectiveWe needed to remove the existing trolley from the crane, take it out for disposal and put a new trolley on the bridge—all with limited time and space. The project had a potential for a 1% bonus on the multiple million dollar contract if the work could be carried out with no safety incidents. We were ready to take on the challenge.

Dressed in protective gear to shield us from the contamination, we lifted the 40-ton trolley off the girders from below, and then rotate it to bring it down into the constrained space. Once we removed the girder, the area was decontaminated so we could do the rest of the modernization in our street clothes. We then installed a new custom-designed crane system that would fit their facility and meet the new standards. The entire modernization was completed in 11 weeks, and our safe, efficient work earned us the safety bonus.

A safer, more efficient workplaceWritten from the customer’s perspectiveKonecranes proved they are the experts in the crane field. They really pulled off a tremendous project here. Our new system has two hoists, designed to perform balanced tandem lifts. Also, they installed a custom hook on our bottom block, so now we can lift all types of containerized loads—no matter the shape, size or source. Overall, I couldn’t be more pleased with the modernization.

warNING! extreme CraNe maKeoVer aHead!



Several months ago, we invited Konecranes to our quarterly maintenance management meeting to present a Gear Case seminar to maintenance managers from our nine plants in Oklahoma.

Konecranes showed us how important it is to have our gear cases inspected regularly. We quickly learned in the seminar that small cracks in the gears can lead to serious maintenance and operational matters, including in some instances, unexpected load drop. unlike other crane issues, this is a “silent killer;” there’s no noise, no indication whatsoever—the load just drops!

Due to age and duty cycle, our cranes were at risk. We decided that each crane needed an in-depth, open gear case inspection to detect any defects or deficiencies that cannot be seen during standard visual inspections.

We knew right away that we needed to work with Konecranes to develop an inspection plan—we didn’t want to experience a catastrophic failure! So far, we have had gear case inspections for four of our locations, and inspections are lined up for the rest.

CreatING a LoNG-term maINteNaNCe mINdset

Case study

oNe CraNe at a tIme...How a KoNeCraNes CraNe CaN HeLp saVe tHe worLd

Testing massive bladesWind turbine blade testing is critical to maintaining high standards of reliability and meeting international certification standards. As they were designing the testing facility, the Massachusetts Clean Energy Center realized they needed an overhead crane to transport the turbine blades to the facility. Their testing facility would be the first in the united States to allow researchers to test blades up to 300 feet in length—roughly the length of a football field.

The right crane for the jobKonecranes won the order to provide a 50-ton crane, with two 25-ton auxiliary hoists, by providing the most advanced features at a cost-effective price. The two-speed crane was equipped with synchronization features, which allowed the hoists to operate in tandem, maximizing the lifting capacity of the crane.

Promoting clean energy Without the overhead crane, it would be impossible to verify the quality of the blades. The tests reduce the need for costly and time-consuming repairs to damaged blades. Thanks to their successful crane installation, Konecranes has helped create a future in clean and alternative power generation.

Company Information: The Massachusetts Clean Energy Center’s Wind Technology Testing Center is the first in the united States to test turbine blades up to 300 ft. in length.


Case study: CRANE DETECTIVE

Mysterious motor failure For years, Konecranes had been servicing the crane motors at an energy-from-waste facility. Suddenly, the motors started failing—in just a few short weeks, five or six motors mysteriously failed.

The Konecranes crane detective takes the case Right away, I met with the customer and the consultant who designed the motors to search for clues.

The first thing I asked for was a duty cycle analysis. If an employee had been abusing the equipment—like slamming the grapple or something of that nature—the report would tell us. Furthermore, if the motors were experiencing any type of abuse, I would be able to deduce during which shift the damage had occurred.

I spoke to the plant manager as well. We soon discovered there was a sudden surge of current into the motors—50% more than usual. After calling the Philadelphia service branch, I determined the spike in electricity was caused by an error in the controls. After I adjusted the controls, the problem was corrected.

Another case closed!

tHe adVeNtures oF tHe CraNe deteCtIVe:tHe motor FaILure mysteryeNerGy

From waste


Case study

puLp & paperThe squeaky monorail The monorail crane system at the paper plant winds around the mile-long facility, with sharp turns, similar to a maze. The tight 90 degree corners of the system are critical for maneuvering rolls of paper throughout the building.

When employees at the plant began hearing high-pitched squealing noises coming from the crane, they instantly began to worry.

The self-diagnosis Immediately the plant was convinced the rails were the problem. If this was the case and the rails needed to be replaced, they would have to shut down the line for weeks. With downtime costing upwards of $25,000 per hour, the plant was in a panic. Luckily, they called Konecranes to make the emergency repair.

The doctor steps in Konecranes sent in one of their most experienced technicians. He diagnosed the problem in less than two hours: it wasn’t the rails that were the problem—it was the wheels, which had worn down and needed to be repaired. Moving quickly, he made the repairs in as little time as possible, which saved the plant thousands of dollars in downtime and lost productivity.

wHeN seLF-dIaGNosIs Goes wroNG, CaLL KoNeCraNes


Case studyCase study

out wItH tHe oLd, IN wItH tHe New:New CraNe NearLy eLImINates BreaKdowNs Company Information: With facilities in more than 20 countries, Ahlstrom is a high performance materials company that partners with well-known global businesses to provide products such as filters, wall covers, flooring, labels and food packaging.

A crane past its primeThe 40 year-old dry end crane at an Ahlstrom facility in Brazil was not designed to function in the dusty environment of a paper mill. Without dust-proof enclosures or air conditioning, the electrical controls and components deteriorated at an accelerated rate. The crane still used its original contactor controls, which did not have precise speed control options necessary for careful load positioning and ultimately caused premature wear to the gears, motor and brakes. As a result, the dry end crane broke down on a monthly basis.

Ahlstrom made plans to rebuild the crane, but quickly encountered a major obstacle: due to the crane’s age, many parts were obsolete and would need to be custom-made. The crane was critical to production and could not be out of service for an extended period of time.

New crane proves its worth Konecranes successfully demonstrated the value of purchasing a new 20-ton capacity, three-trolley dry end crane. The crane’s sealed enclosures protected against water, humidity and dust. The new inverter technology placed less stress on internal components, minimized equipment wear and reduced load sway.

To minimize downtime, Konecranes technicians installed and commissioned the new crane before removing the old crane during scheduled downtime. This strategic installation allowed Ahlstrom to remain productive throughout the entire process. Since its installation five months ago, the crane has not had a single breakdown.

Not your average upgrade A paper company in Southern California asked Konecranes to install a new power bar system, but there was a catch: the crane would need to remain in service throughout the entire project. Furthermore, the power bar was located above the drive controls for the paper machine, which would make accessing the conductor bar difficult.

Konecranes devised a plan for their workers to remain safe during the installation, keep downtime to a minimum, and meet the tight, 10-day deadline.

Successful installed ahead of scheduleThinking creatively, the Konecranes technicians built a workstation platform on the crane with scaffolding, which gave them complete access to the conductor bar. To reduce the risk of electric shock while working, the technicians mounted conductor staff on the end truck and runway rail to maintain constant ground.

In the high heat paper mill environment, the technicians replaced the rusted metal clips with more substantial ones, and installed a heavy-duty conductor bar along the building. The new four conductor bar system was insulated, finger-safe and met OSHA safety requirements. Konecranes completed the project in only seven days—three full days ahead of schedule.

CreatIVe power Bar repLaCemeNt Keeps paper mILL GoING stroNG


Case study

From twenty pinches to a single “bite”A paper mill in California previously offloaded wood yard sites with an excavator, which was not efficient for loading and unloading trucks. The excavator’s set of pinchers took 20 pinches to unload a truck filled with wood. So, the company decided to try a rotator crane from Konecranes, which operates from an 80-foot tall tower on a circular track and can offload an entire truck in a single bite.

The paper mill was excited to have the crane—it would save hours every day. There was only one problem: no one in the facility knew how to use it.

Konecranes provides hands-on training The Konecranes Training Institute was thoroughly prepared to train the team on the operation of the crane. After a presentation on crane safety and an overview of the crane’s features, the employees’ curiosity was peaked. The Konecranes instructors then moved into hands-on operator training where the crew learned how to offload a truck in only two minutes, while maintaining complete control of the load.

KoNeCraNes Goes tHe extra mILe wItH operator traINING

“Thanks to Konecranes, we not only have quality equipment, but we also know how to operate it safely and efficiently. To me, that’s just as important.”

Paper Mill Manager


I would like to send a sincere thanks to our Konecranes on-site manager for going above and beyond at our paper plant. He spoke up about a safety issue when he noticed a cord reel electrical outlet sitting in water. It should have been on a ground fault indicator, as we require. If he had not mentioned it, we would not have found it, and one of our guys could have been electrocuted, or suffered a serious electric shock. This went far beyond simply caring about our equipment—he was watching out for the safety of the entire plant. We were very fortunate that he spotted this safety issue before anyone was injured, and for that, all of us at the plant are truly grateful!

union Chief Steward

a satIsFIed Customer sHares HIs storyKoNeCraNes to tHe resCue


Case study

INtermodaL & raIL

worKING toGetHer to ImproVe eFFICIeNCy aNd saFety

A solid, trust-based relationship The Huntington Service Branch has built a solid relationship with the local CSX Locomotive Shop over the past five years. Recently, we sat down with them to discuss the benefits of Non Destructive Testing (NDT) of hooks and below-the-hook devices, with a specific focus on the existing 250-ton J-Hooks that are used to lift locomotives in the facility. CSX agreed this inspection process would improve the efficiency of their operations and the overall safety of their cranes.

Inspection reveals a cracked hook We worked with CSX to develop an inspection process that would not interfere with their day-to-day business. Our technicians completed the testing of the J-Hooks in just one day.

NDT revealed that one of the J-hooks was cracked. The Konecranes inspector contacted an engineering office to evaluate the hook and determine whether or not repairing the hook was a possibility. The engineering department approved the repair, the work was completed over the weekend, and the hook was returned to service on the following Tuesday.

Success leads to proactive maintenance Because the repair only caused production to be down for one day, the CSX plant was extremely pleased with the outcome. To prevent any hook-related issues in the future, the J-Hooks for the 250 ton crane are now checked annually. Since the initial repair, there have been zero lost production days from hook-related issues.

Company Information: CSX Corporation, one of the united States leading transportation suppliers, provides rail-based transportation services, including traditional rail service and the transport of intermodal containers and trailers.


Case studyCase study: CuSTOMER’S PERSPECTIVE

A major decisionAt our railroad yard, our trains and repair shops never rest. We stay busy 24 hours a day, seven days a week. With the fast-paced nature of the railroad, our lifting equipment needs to be kept in peak condition at all times—we can’t afford to have any breakdowns.

So, you can imagine how frustrated we were when one of our critical overhead cranes started vibrating violently. We needed to get this crane back into service right away, so we contacted several crane companies, hoping to fix the problem as soon as possible. We soon discovered we were going to have to replace the entire hoist—a repair that was going to be both extremely expensive and time consuming.

We didn’t want to spend the money on a brand new hoist without exploring every option, so we called Konecranes for a second opinion. We wanted to make sure that a replacement was absolutely necessary.

Konecranes proved to be the right choiceGood thing we called Konecranes, because it turns out we didn’t have to replace the hoist! Konecranes technicians performed a visual inspection on the open gear case to find the source of the malfunction. After looking at the gear case, they showed us that the gears were improperly timed. In a matter of hours, Konecranes technicians reassembled the gears into the proper positions.

Overall, our decision to call Konecranes was the right one. Their fast repair saved us thousands of dollars and weeks of unnecessary downtime to replace the hoist. Now, our hoist functions properly, and we haven’t had any breakdowns.

tHe seCoNd opINIoN tHat saVed us tHousaNds oF doLLars

Too dark...At a busy locomotive shop, workers relied on an overhead crane to repair locomotives, but the crane could not be used at night, when the sky was pitch black. Due to an increase in customer demand, the shop needed to begin running the crane at night.

The shop decided that lights would allow them continued use of the crane after the sun went down. So, the locomotive shop ordered two Konecranes jib cranes with 5-ton capacity hoists, with bright lights that shined all night.

Too heavy...But, day after day of moving the manual jibs grew tough. The heavy loads grew cumbersome. Productivity began to decline. The shop needed to find a way to make the cranes more efficient.

So, Konecranes modernized the jib cranes to include motors.

Just right...The shop now has the proper means to perform the needed tasks thus increasing the level of productivity at the facility. The motorized jib unit allows the staff to effortlessly move the materials with precision. In addition, employees were able to increase the total throughput of the facility by increasing the number of units repaired in a set period of time.

The locomotive shop is pleased to have a crane that is just right.

FINdING tHe CraNe tHat Is “Just rIGHt”


Case study

steeL & prImary metaLs

maKING VINtaGe CraNes a tHING oF tHe past

Vintage cranes in need of modernization AM Castle Metals owned two vintage 20-ton P&H™ cranes built in 1968 that were already in place when they bought the facility. The cranes ran on open span copper wires attached to the bridge which posed a potential electrocution hazard to anyone working around the crane with a forklift. In addition, the constant vibration of over 40 years of use had caused broken wire and switch issues, and parts were becoming difficult or impossible to find for the wound-rotor controls.

updating cranes with this millennium’s technology Modernization specialists from Konecranes developed a solution. They recommended replacing the 1968-era magnetic controls with modern variable frequency drives, designed to provide smooth acceleration and deceleration speeds, reducing wear and tear on the drive train and decreasing load swing.

To avoid lost production time, Konecranes scheduled the modernization so the plant experienced no downtime, and both cranes were back in service within a week. More importantly, a modern festoon system with closed circuit switching replaced the open span copper wiring, enhancing the safety of the working environment.

Modern crane reduces breakdowns by almost 100%Prior to the modernization, $15,000 was spent in 2008 and again in 2009 on repair and maintenance on this crane. After the modernization, throughout 2010, repair costs were zero. According to AM Castle Metal’s operations and quality manager Jerome Mead, they have not experienced a single breakdown or lost crane hour since the work was completed.

Company Information: AM Castle Metals supplies specialty products in bar, tube, plate and sheet to metal users worldwide.

IF YOuR CRANE HASN’T BEEN uPDATED SINCE NIXON WAS PRESIDENT, THEN IT’S PROBABlY TIME FOR A CHANgE.

“Konecranes provided us with a much safer way to run our cranes. We have gained in productivity, safety, and we’ve had no inspection or detection problems since we’ve done this work. There have also been no repairs whatsoever. In the long run, this modernization is going to save us a lot of money. And when it comes to safety, we can’t put a price on it. That’s priceless.”

Jerome MeadOperations and Quality Manager


Case study: THEN & NOWCase study: SALESPERSON’S PERSPECTIVE

a satIsFIed Customer sHares HIs story

To Whom it May Concern:I am writing this letter on behalf of Brannon Steel concerning one of your technicians. I would like you to know that he is one of the most requested technicians for service calls at our facilities at all times. And there are many reasons for this. Not only are his skills second to none as far as we are concerned, but also his positive attitude and willingness to help make him a delight to work with. He is constantly giving us advice and teaching us how to better take care of our equipment. I would describe this gentleman as the perfect representative of your company and we are sure you are very proud to have him and other great technicians like him on your staff. When we look for suppliers and service providers, one of the major things we are looking for is people we enjoy working with. So, keep up the good work!

Sincerely, Dave Lee Special Projects Manager Brannon Steel

Company Information: Since 1968, Brannon Steel has been an industry leader supplying quality carbon steel parts to OEMs and custom fabricators throughout Canada and the united States.

Then…This steel manufacturing plant relied on 20 double-girder, top-running cranes and two stacker cranes to handle slit coil. Installed when their facility opened in 1965, these cranes were equipped with single-trolley magnetic five-step controls operated from a pendant station. Because the plant was only handling coils, a single C hook was enough.

Things were about to change at this plant. They needed to be capable of working with long pieces of structural steel and pipe up to 60 feet long—meaning they needed to add a second hoist to each crane to lift these long pipes. In addition, the plant decided it was time to upgrade their drives and controls to improve the operation and reliability of their cranes.

Now…Since they had been providing superior maintenance service and minor crane enhancements to the plant for many years, Konecranes won the bid over three other companies to complete the upgrade. The plant had confidence that Konecranes would complete the modernization in a professional manner and on time. In just six weeks, Konecranes equipped the first of three of the plant’s cranes with rebuilt trolleys, new inverter controls, festoon wiring, bridge motor and gear reducers and radio control. The other two cranes followed immediately after the first one was finished.

Brand new inverter drives allow the cranes to run smoothly and efficiently. Rather than using pendant controls attached to the crane, operators are now safer and more mobile with the new radio controls. The plant is so pleased, they are making plans to upgrade the rest of their cranes.

KoNeCraNes perForms muCH-Needed upGrade

“Thanks to Konecranes’ upgrades, our plant is more productive than ever. The new drives and radio controls make it so much easier to operate our cranes—and as soon as the new hoists were installed, we started moving pipes by the truckload.”

Plant Manager



GettING BaCK oN traCK wItH raILq

Six years ago, our plant was faced with the challenges of old equipment: around 60% of our production cranes are over 40 years old, which led to major crane alignment problems, resulting in squeaky wheels. Overall, we used to have a lot of plant-wide crane issues, and we were constantly changing wheels, cables and bearings. When the cranes went down, we stopped moving.

Konecranes technicians performed a RailQ runway survey, which showed us graphs of the railway alignment. That’s when we found out that the wheels weren’t the problem. We used to replace crane wheels fairly frequently, but RailQ showed that we needed to replace the crane rail in several bays and adjust the elevation. Since then, we haven’t needed to replace any wheels.

As long as annual inspections continue, we can now expect crane wheels to last a long time. In any case, I’ll be long gone by then! Konecranes workers, along with the RailQ survey, have really made a huge difference. In the past two years there have only been about three times when I’ve had to use my engineers to get a crane working again. Previously, it was every day. Now, we have hardly any unscheduled downtime.

Company Information: The Aluminum Company of America (Alcoa) is the world’s leading aluminum producer, spanning 31 countries and providing services to several industries, including aerospace, automotive, packaging, construction and commercial transportation.

Case study

gear case implosion catches foundry off-guardDeep in this hot, dusty foundry, a 30-year-old hot metal crane mass-produced nearly 50 engine blocks every day. One day, the gear case suddenly imploded, leaving employees stunned.

“We heard a booming noise from the gear case,” an employee described. “Then the crane started skewing so badly, we thought it might come off the track!”

Because the foundry could potentially lose millions of dollars in lost production time, they gave Konecranes a tight, two-week deadline to complete the massive repair.

A crane in desperate need of an upgradeThe problem was obvious to the Konecranes technicians: the crane was performing more rigorous lifts than its intended design.

“It’s not surprising the gear case failed. This was a Class ‘D’ crane performing the work of a Class ‘F’ crane,” explained a Konecranes technician.

After upgrading the gearing, the technicians performed inverter upgrades to reduce wear on internal components and improve speed control options. As a final boost to enhance safety, the technicians upgraded the radio controls, to function with the new inverter drives, allowing the operators to lift and tilt the ladle from a distance, keeping them further away from the blazing furnace.

Working 16 hour days, the Konecranes team completed the repairs and upgrades in only 10 days—four days ahead of the deadline. It has been year since the upgrade, and downtime at the plant has significantly decreased.

KoNeCraNes saVes aN oVerworKed CraNe wItH a speedy upGrade



The charge ladle crane was commissioned in 2005, but vibration on the main hoist became a problem in the last few years. Eventually, the hoist had to be taken out of service. Several service companies, along with steel plant personnel, could not solve the problem. Frustrated the issue still hadn’t been fixed, they called Konecranes—the original manufacturer of the crane. After spending thousands of dollars to repair this crane, they wanted another opinion, so we agreed to take a look at the crane. As the OEM, we had access to all of the documents we needed to assess the situation. After my initial visit, I called the “Crane Doctor,” one of our best Engineers, hoping he could provide some insight.

Without even looking at the crane, he told me over the phone what he thought the problem was and assured me he’d be able to fix it. As we drove to the plant, he said, “I can’t wait to hear what they have to say when we finally fix this problem.”

As soon as he looked at the crane, he showed where the shaft had split due to severe misalignment. After seven hours of shimming, checking gear mesh and making alignment changes to gear sets both vertically and horizontally, the crane ran smoothly and quietly. The steel plant was amazed at how quickly and accurately the “Crane Doctor” corrected the problem.

tHe “CraNe doCtor” suCCessFuLLy reVIVes aNotHer CraNe

“This was excellent work done in a very short period of time, and I would recommend this engineer’s services to anybody, anytime to solve very difficult problems.”

Steel Plant Manager

Case study: THEN AND NOW

Then …Heavy crane causes worker strainThe overhead crane in this facility made the metal finishing process hard work. Every day, their staff would gather together to roll the 3-ton, under-running girder crane into place. Once the device was pushed initially, it moved steadily. unfortunately, as the laws of physics would explain, once it gained speed it could be difficult to stop.

The manufacturing process involved two chemical production lines, where parts passed from basket to basket and from tank to tank in order to achieve the appropriate finish. The crane’s movements were not smooth, which resulted in the metal parts being dropped into the chemical solution—making it necessary for employees to “fish” out the dropped items.

After the metal was dipped into the solution, there was not an effective draining method. using a forklift, the tubes were removed from the basket and propped up against a skid to drain. Between the heavy crane and the less-than-ideal draining process, the production process was time-consuming. Customer demand was increasing, and the challenges derived from the crane were proving to be unacceptable.

The metal processing plant desperately needed a new lifting device to enhance the safety of their employees, improve ergonomics and streamline production.

Now …XM Workstation Cranes reduced worker fatigue and improved productionWith two new Konecranes XM workstation cranes with radio pendant controls, the situation at the plant is much different. Now, the cranes travel the 180 foot length of the runway with just the push of a button.

The new cranes were easily integrated with existing spreader bars and baskets. The advanced radio controls allow the operator to isolate the hoists individually or use them in tandem. By isolating the hoists, the operator can raise one end of a suspended load higher than the other to drain the tubes directly over the tank, which keeps the floor drier and minimizes solution waste. With better lifting control, the employees no longer have to retrieve dropped items from the chemical tanks.

The XM workstation cranes have helped double production at the facility. Instead of only coating two items at a time, the new configuration allows for at least four items to be processed simultaneously.

wLs CraNe ImproVed produCtIVIty wItH adVaNCed erGoNomICs



Jib cranes not getting the job done In our manufacturing facility, we had several jib cranes that we relied on to load barrels of welding wire onto skids. To keep up with our busy production schedule, we need to move about 50 barrels a day. Our jib cranes were outdated and not performing correctly. If one of the cranes broke down, we couldn’t manually lift the heavy barrels. Instead, we had to use fork lift trucks—an operation which was slow, cumbersome, inefficient and unsafe.

We knew we needed to upgrade our current system. Since Konecranes had been performing our monthly inspections, we decided to contact them and order three new XM cranes.

Konecranes makes vast improvements When Konecranes technicians arrived to install our new cranes, they showed us that our original cranes hadn’t been installed properly—no wonder we were having so many problems!

Konecranes didn’t stop with the new crane installation. At our plant, we also use a monorail system to load and unload reels of welding wire—but because it wasn’t up to code, we had decided to stop using it altogether. Konecranes extended the system and made the necessary repairs so that it was fully functional. Since then, we haven’t had any crane-related issues, and our plant functions better than ever.

KoNeCraNes Keeps us oN traCK

Case study: MANAGER’S PERSPECTIVE

Rapid motor failures For the past several years, we have been working with a steel company that operates class E cranes in a high heat environment. Konecranes Crane Pro Parts motor shop had been servicing their powerful crane motors to keep the cranes in top condition. So, when some of the rebuilt motors began to fail within days of installation, we had to work quickly to determine the cause.

Finding the root of the problem I dug into the problem, along with a salesperson and an outside motor design consultant. We discovered the motors were experiencing problems because the controls were not set up properly. Our service technician came in over a holiday weekend to check the controls set-up, test in-rush currents and examine other critical values. He made several adjustments to the controls during the visit that have improved the service life of the rebuilt motors.

In addition, we suggested the customer improve the cooling and brushes on the motors so they could stay in top condition and would be less likely to break down.

restorING LIFe to HIGH-powered motors

“Thanks to Crane Pro Parts, our motors are performing at a much higher level and are lasting a lot longer—and we are confident our cranes are in the best hands possible.”

Plant Manager


INdexCRANE SERVICEMAINMAN®Concrete Company ........................... 14Manufacturer of Automobile Interior Mechanisms .................................... 16Piper Valve Systems ......................... 20Manufacturing Facility ...................... 25Brewery ........................................... 26Hydropower Plant ............................. 45

gEAR CASE INSPECTIONPower Plant .............................................50

INSPECTIONSHouston, Texas Oil Refinery .............. 40CSX Corporation .............................. 61

MODERNIZATIONSChemical Plant ................................. 27Engineering Company ....................... 39Oil Refinery ...................................... 41Los Angeles Department of Water and Power .......................... 43Coal-Burning Power Plant .................. 48Power Plant ......................................... 49AM Castle Metals ................................ 65Steel Manufacturing Plant ................ 67

PREVENTIVE MAINTENANCEAutomotive Facility ........................... 11Toyota Lift of Minnesota ................... 18

RAIlQAlcoa............................................... 69

REPAIRSAutomotive Stamping Plant ................. 7Automotive Stamping Plant ................. 8Manufacturing Facility ...................... 15Brewery ........................................... 26Hydroelectric Plant ........................... 44Energy-From-Waste Facility ............... 53Paper Plant ...................................... 55Southern California Paper Company .. 57Railroad Yard ................................... 62Brannon Steel.................................. 66Foundry ........................................... 68Steel Plant ...................................... 71

INDuSTRIAl CRANE SOluTIONSAhlstrom ............................................. 56California Paper Mill ......................... 59

PARTSElectrical Components Factory .......... 33Los Angeles Department of Water and Power .......................... 46Steel Company ................................ 72

INDuSTRIAl CRANE PRODuCTSAssembly Factory .............................. 9Leading Manufacturing Company ...... 13Schlumberger Technology Corp. ........ 22Automated Material Handling Facility ..... 23ACCIONA ......................................... 47Massachusetts Clean Energy Center’s Wind Technology Testing Center ........ 51

SAFETYPaper Plant ...................................... 58

lIFT TRuCKSToyota Material Handling .................. 32

WORKSTATION lIFTINg SYSTEMSEngine Assembly Plant ..................... 10K.K. Tool Company .......................... 17Manufacturing Facility ...................... 19Piper Valve Systems ......................... 20Manufacturing Facility ...................... 21Component Manufacturing Facility .... 24Brewery ........................................... 26Bottling Factory................................ 29Fabrication Plant .............................. 31Pound Cake Factory ......................... 30Tencate Advanced Armor ................. 35Christie ........................................... 34Locomotive Shop ............................. 63Metal Processing Plant ..................... 70Manufacturing Facility ...................... 73

TRAININgOffshore Drilling Components Manufacturer ............... 28

MACHINE TOOl SERVICEPatterson Pump ............................... 37

76 Konecranes • More Happy Customerswww.konecranesuSA.com

Konecranes is a world-leading group of Lifting Businesses™, serving a broad range of customers, including manufacturing and process industries, shipyards, ports and terminals. Konecranes provides productivity-enhancing lifting solutions as well as services for lifting equipment and machine tools of all makes. In 2012, Group sales totaled EuR 2,170 million. The Group has 12,100 employees at 609 locations in 47 countries. Konecranes is listed on the NASDAQ OMX Helsinki (symbol: KCR1V).

© 2013 Konecranes. All rights reserved. ‘Konecranes’, ‘Lifting Businesses’ and are registered trademarks of Konecranes.

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