When your overhead crane and hoist system breaks down, your entire operation is disrupted. A single breakdown can halt production, create costly delays, and put your employees at risk. While equipment failure can result from many factors such as improper installation, operator error, rigging failures, and overloading, the good news is that most issues are preventable with proactive measures. By focusing on proper training, inspections, and safe operating practices, companies can significantly reduce the risk of breakdowns and keep their equipment up and running. 

Here are eight ways to help prevent equipment breakdown:

 

1. Train Operators

A well-trained operator is essential for the prevention of equipment breakdowns. 

Operators should have a thorough understanding of equipment functions, limitations, and safe operating practices. They should be able to recognize load distribution and center of gravity, apply proper rigging methods, conduct thorough pre-operational inspections, and respond appropriately in emergency situations. Trained Operators must also communicate clearly with ground personnel. 

Ongoing training ensures operators stay current with standards and remain confident in making decisions. 

2. Conduct Regular Inspections

Regular inspections catch small issues before they become big problems. These inspections occur at multiple levels:

• Pre-operational checks occur daily by operators looking at hoists, brakes, wire ropes, controls, etc. for damage. 
• Frequent inspections are performed by operators or designated personnel daily to monthly. 
• Periodic inspections are thorough evaluations that occur at least one time per year and require full documentation.

Maintaining inspection logs creates a history of potential problem areas and helps teams identify recurring issues.

 

3. Prioritize Preventative Maintenance

Preventative maintenance keeps equipment performing at its best and reduces the chance of sudden failure. This includes lubricating moving parts, replacing worn-out components, performing adjustments and minor repair, and scheduling modernization or upgrades when needed. 

4. Follow Safe Rigging and Lifting Practices

Even the best-maintained crane can fail if loads are handled incorrectly. Operators must assess the load’s weight, dimensions, and center of gravity. They must choose appropriate rigging gear, adhere to load limits, ensure loads are balanced and secure, lift loads smoothly avoiding sudden swings, and maintain clear communication with ground personnel. 

5. Using Quality Equipment

Using quality equipment is one of the simplest and most effective ways to prevent breakdowns. High-quality parts are built for consistency, heavy loads, and long-lasting performance. Cheap or poorly made products can wear out faster and create unnecessary strain on your system, and can lead to unexpected downtime. Investing in trusted brands and purchasing quality materials will reduce repair costs and improve productivity over time. 

6. Right Equipment for Job

Having quality equipment is important, but using the right equipment for each task is just as critical. When parts are used outside of its intended purpose or capacity, it increases stress on the system and heightens the risk of failure. Before using a piece of equipment, operators should confirm its capacity, configuration, and environment suitability. Using the right tool for the job not only protects your equipment but also keeps your team safe. 

7. Clear Communication and Signaling

Many breakdowns and accidents occur when communication fails. Operators should always have a clear line of sight to ground personnel and use universally understood signals. Whether through hand gestures or radios, instructions must be clear without any confusion for safe lifting. 

8. Having a Safety First Mindset and Culture

At the core of preventing equipment breakdown is a company’s commitment to safety. Following established safety policies and procedures ensures that inspections are completed, maintenance schedules are followed, and operators adhere to load limits and rigging standards. 

A strong safety culture means inspections and preventative maintenance are non-negotiable, operators and technicians hold to OSHA, ASME, and company standards, communication is clear, and people are prioritized over production.

Equipment breakdowns can be disruptive and costly, but they are not inevitable as they can be prevented when taking proper action. 

At Engineered Systems, we support customers with crane inspections, maintenance programs, and training classes to protect your people and your equipment from breakdowns. Contact us today to learn how we can keep your overhead crane and hoist equipment safe and productive.