Case Study: Pilot Installation at a 24-Crane Metal Production Facility
Summary
At a metal production facility with 24 overhead cranes, Hoistack was commissioned as a pilot to close the visibility gap caused by manual maintenance tracking. In the pilot, operating status, running hours and fault notifications were monitored on one panel.
The Facility and the Challenge
The facility ran 24 overhead cranes across multiple shifts under variable load. Maintenance records were kept in notebooks and Excel; how much each crane ran was unclear. Faults were mostly noticed during site walks, which led to unplanned downtime.
Pilot Installation
The pilot started on the crane whose downtime was most critical. The field device was installed on the existing panel without stopping production and web/mobile panel access was set up. A monitoring period of about 30 days was planned.
Data Monitored
- Running hours and usage per crane
- Current, speed and temperature signals
- Fault and alarm events (timestamped)
- Data buffered during offline periods
Visibility Gained
During the pilot the team could see at a glance which crane was running, idle or in fault; fault events were notified instantly and event history was logged. So maintenance began to be planned on real usage rather than the calendar, and early detection of unplanned downtime became possible.
This case study is anonymized. Numeric results vary by facility; we can run a pilot assessment for your own fleet together.
Next Steps
After the pilot assessment, the system was planned to expand gradually to the facility's other cranes. A similar pilot process can be designed for your facility too.
Frequently Asked Questions
Can a pilot be set up for my facility?
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Yes. A short pilot starting with a single crane is designed and expanded to the fleet based on the results. You can start from our pilot demo page.
Are results the same at every facility?
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No. Gains vary by the facility's number of cranes, usage and existing processes; that's why an assessment is done first.
Let us prepare a free crane tracking demo tailored to your fleet.